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Best Practice 4.lubricant Selection Overview P.1 PDF
Best Practice 4.lubricant Selection Overview P.1 PDF
Lubricant selection:
Bearings,gear drives
and hydraulics
By Mike Johnson, CLS, CMRP
Contributing Editor
L
ubricant selection is a pivotal starting point in the
pursuit of precision lubrication practices. All the
effort applied to clean delivery and handling, filtra-
hlights:
tion, dehydration, alignment, balancing, etc., is lost if the
ic le h ig
Art selecting
lubricant selected for the application cannot support the
ne s f o r -
■ Guideli
machine’s demands. Many criteria must be considered
s fo r p la in and ele when selecting a lubricant for a set of machines or
lubricant gs, gears and machine components.
in
ment bear stems. Lubricant chemistry has an influence on the final
sy
hydraulic decision. The basestock (synthetic or mineral) and the
h e a d d it ive mix additive systems in use (EP, AW, R&O) exert tremen-
■ Analyzin
g t dous influence on the performance qualities of the
ea c h c omponent. lubricant. It is common to have multiple choices for a
fo r
n ic all y accurate given grade and type of lubricant within a product
■ Making
tech n line (i.e., ISO 220EP/SAE 90EP gear oil), with each
lub r ic an t selectio example designed to perform effectively for a set of
baseline i th ou t exacting given conditions.
w
decisions al expressions. The machines themselves have an influence on
ic
mathemat
final lubricant selections. OEMs design and build
machines for general types of service. A gear drive
manufacturer could not possibly consider each and
every type of application for a given make and model
when it begins the design process. Designers can build
18 APRIL 2008 T R I B O LO G Y & LU B R I C AT I O N T E C H N O LO G Y
sufficient durability into the basic design that Regardless of shape and form, all plain bearing
allows customers to use those products for similar components have a common requirement: a full-
uses within widely varying production environ- fluid hydrodynamic film to sustain component life
ments. The nature of the production environment cycles. Two types of decisions must be made:
(wet, dry, hot, cold, abrasive dirt, harsh chemical 1. Viscosity grade according to the machine’s
exposure, steady state or intermittent operation, operating profile.
etc.) influences the degree of effectiveness for a 2. Lubricant chemistry/additive type (R&O, EP,
given lubricant type and grade. AW, Compounded, Tackified).
Plant maintenance strategy has an influence on The viscosity grade considerations for sliding
lubricant selection as well. Where management is surface interaction are rooted in a common set of
particularly forward thinking and willing to invest physical realities. Total available surface area, lin-
in modifications that improve lubricant manage- ear surface speed, surface unit loading, lubricant
ment effectiveness (filter connections, continuous viscosity grade and lubricant replacement rate all
filtration, embedded sample ports, bearing isola- have an influence on the formation of a hydrody-
tors, etc.), the company is positioned to maximize namic oil film.
the superior value that can be achieved through STLE member Bob Scott, manager of Lube-
the use of high-performance lubricants, both min- Works, Ltd., in Calgary, offers a method of lubricant
eral- and synthetic oil-based. selection for plain bearing applications. According
With the variety of factors that can impact lubri- to Scott, the minimum information required for the
cant film formation and effectiveness, it is to the determination of the proper ISO grade for journal
practitioner’s benefit to follow a lubricant selection bearings includes:
process that is objective, repeatable and based on
1. Shaft RPM.
widely recognized engineering practices and princi-
2. Temperature of the oil in the bearing.
ples. This article addresses a formal lubricant selec-
tion process that could be used to make technical- 3. Approximate unit loading pressure (PSI or
ly accurate baseline lubricant selection decisions Newtons / m2).
without using exacting mathematical expressions. Scott adds that it would be best to also have
additional information, including:
Parsing the machine ■ Bearing length, number of bearings and
In the January TLT I proposed cataloging all lubri- rotor weight (to calculate the bearing pres-
cated components within a machine for evaluation sure to verify the load).
and specification of a lubricant. The purpose of the ■ Shaft diameter to calculate the shaft surface
process is to consolidate the collection of machine speed.
components into a concise set of types and catalog
■ Driving horsepower.
which components rotate, slide, pivot or have
■ Knowing whether shock loading is present.
other dynamically interacting surfaces. There are
relatively few unique types of components, but ■ Knowing if the unit is in a warm or cold envi-
there are many permutations of each of the few ronment.
unique options. Let’s address these components ■ Knowing if cooling water is being applied.
by general type that represent most industrial Scott explains there are several different charts
machinery, including: that recommend ISO viscosity grades for journal
■ Plain bearings bearings, and most are based on oil temperature
■ Element bearings and shaft RPM. Figure 1 provides an ISO viscosity
■ Gears CONTINUED ON PAGE 20
■ Hydraulic systems
Plain bearing lubricant selection Figure 1. Viscosity selection chart for ‘medium
Probably the most common manifestation of a load’ applications (150–200 psi)
plain bearing is a round steel journal riding on a Shaft speed Operating oil temperature
conforming one- or two-part brass or babbit bush- 20 C–50 C 60 C 75 C 90 C
ing. There are plenty other machine component 800 rpm ISO 68 ISO 100 ISO 150
types that could be categorized similarly, including 1,200 rpm ISO 46 ISO 68 ISO 100-150
machine tool gibbs (slideways), brass bushing, 1,800 rpm ISO 32 ISO 46 ISO 68-100 ISO 150
pivot pins, ball screws, worm gears, etc. These 3,600 rpm ISO 32 ISO 32 ISO 46-68 ISO 68-100
bushings are similar to plain bearings in composi- 10,000 rpm ISO 32 ISO 32 ISO 32 ISO 32-46
tion, form (shape), and film characteristics.
T R I B O LO G Y & LU B R I C AT I O N T E C H N O LO G Y APRIL 2008 19
CONTINUED FROM PAGE 19
Element bearing lubricant selection 2. Determine the bearing’s limiting speed fac-
There are many types of element bearings, includ- tor. This value is referred to as the “pitch line
ing ball, roller, spherical roller, thrust roller, needle velocity” or the “nDm.” Figure 5 shows the
roller and single- and double-row types. Fortunate- speed limit calculation for element bearings.
ly the selection process for the various types is Bearing speed limits differ for each bearing,
similar. The following discussion pertains to the but general rules exist around bearings by
common ball, roller, spherical roller and thrust bearing type and function.
roller type element bearings. Figure 6 provides practical speed limit val-
Element bearings operate under a wide array of ues for four common bearing types. Any
temperature, speed, load and environmental con- given bearing may have a unique value for its
ditions. The first step is to select an appropriate given quality, but these table values ade-
viscosity grade followed by selection of additive quately represent range limits for decisions
type (R&O, AW, EP). for selecting either oil or grease lubrication.2
Bearing manufacturers provide fairly useful Example: The 6320 roller bearing turning
charts that assist us with this process. The five at 1,200 rpm has an nDm (speed limiting)
steps to this process are: value of 120,000. This information is particu-
1. Determine the bearing physical size (width, larly useful to assess whether the bearing
outer diameter, inner diameter), element type should be lubricated by oil or grease. Equip-
(ball, cylindrical roller, spherical roller, thrust ment operators often convert oil-lubricated
ball or roller) and shaft speed. These details bearings to grease, even though the operat-
often can be found in the shaft RPM machine ing speed of the bearing is beyond that which
construction diagrams and drawings. Exam- is considered safe for grease lubrication.
ple: A 6320 bearing has a bore dimension of Grease type and relubrication volumes and
100 mm, an outer diameter dimension of 215 frequencies should be adjusted to maintain
mm and a race width of 47 mm. CONTINUED ON PAGE 22
Figure 7. Element bearing viscosity selection Figure 8. Operating viscosity for mineral oils
graph (with a VI of 100)
machines
terminates at Point C, this bearing’s required
s e t of
for a viscosity in centistokes. This element bearing
Gear drives can be lubricated with either grease selection guidelines that conform to the current
or oil. Gear type, size and function are the leading AGMA standard for industrial gear lubricant, Stan-
factors in this decision. While the great majority of dard 9005-EO2. In most instances gear drive hous-
industrial gear applications operate in an oil bath, ings include selection advice on the gear case
some gears operate without one. These gears, itself. Figure 11 shows how the information is dis-
called ‘open’ gears, are lubricated with specialized played on a common gear drive.
greases that are sprayed onto the gear set on an Over time reliability engineers may have to
intermittent basis or applied manually (grease revisit the lubricant selection following a change
gun, brush, spray can). Open gear lubrication will from the original operating state. In these
be addressed later in this series. instances, there needs to be a relatively uncompli-
Once again, viscosity is the central feature of cated and accurate way to estimate the target
the lubricant that must be accurately identified lubricant type and grade. AGMA standard 9005-
and selected in order for components to achieve EO2 for lubricant selection is a helpful document
their expected life cycles. As is the case with the to support effective lubricant selection and will be
previously evaluated components, the oil must referenced for the balance of this selection
possess viscometric properties that cover cold- process.
flow requirements at low starting temperatures AGMA promotes viscosity selection based on
and provide sufficient oil thickness at normal oper- the pitch line velocities of each gear reduction.
ating temperatures to resist the squeezing effect of Pitch line velocity (PLV) is calculated based on the
the meshing gears. following formula:
The low temperature flow requirement is depend- PLV, meters/second = (Gear pitch diameter
ent on a variety of application-specific factors, in millimeters X Gear rpm) ÷ 19098
including weather, degree of shelter (indoor, out-
The gear pitch circle dimensions and shaft speeds
doors), presence of thermal controls and likelihood
must be known in order to make these calcula-
that the unit will be started at extreme (cold) condi-
tions. These values can be provided by the drive
tions. A safe pour-point limit for gear oils is 10 F/5.2
manufacturer or derived from other tooth form and
C below the coldest likely starting temperature.4
ratio data.
Most modern gear OEMs provide lubricant
Once known, the PLV can be correlated to tables
from 9005-EO2, Appendix B, to reference the re-
quired viscosity by ISO grade for a given sump tem-
Figure 11. Gear drive faceplate label showing perature and for the referenced gear tooth forms.
viscosity parameters Consider the following example for a drive on a
wire-drawing machine, as seen in Figure 12:
Step 1..
Determine the dimensions of the bevel gear set:
■ pinion pitch diameter of .032 meters
■ bull (driven) gear pitch diameter of .093
meters.
Step 2..
Measure or calculate the gear shaft speed (pinion
= 3750, bull= 350 rpm).
Step 3..
(Courtesy of Advanced Machine Reliability Resources)
Step 4..
Calculate the PLV of each gear.
Step 5a..
Using the appropriate table from the 9005-EO2
standard, locate the column for PLV and the row for
oil sump temperature. The appropriate oil grade is
found where the column and row intersects.
24 APRIL 2008 T R I B O LO G Y & LU B R I C AT I O N T E C H N O LO G Y
Step 5b..
If the lubricant under consideration is a synthetic, Figure 12. Gear oil viscosity calculation and selection
use the table that corresponds to the high viscosity
index (VI) property. Figure 13 corresponds to 9005-
EO2, Table B-3 for synthetics oils with VI = 160.
When multi-stage reductions produce PLVs that
are at least one or more standard ISO viscosity
grades apart, the owner must rationalize the selec-
tion based on lubricant application (force feed vs.
splash feed), risk imposed by likely load, risk im- (Courtesy of Advanced Machine Reliability Resources)
posed by temperature spikes and risk of cold start-
up to arrive at a final selection. In this exercise,
where there is a high pinion speed, low heat loads
Figure 13. AGMA Standard 9005-EO2
and little risk of load spikes, the preferred mineral
oil selection would be an ISO 150, and the pre-
(Appendix B, Table 3.)
ferred synthetic oil selection would be an ISO 100.
A synthetic VG 150 also would be acceptable. Bear-
ing viscosity selection should be evaluated for all
gears with high operating speeds or temperatures.
The 9005 standard provides additional charts
that are useful for selecting lubricant viscosity
grades for worm gears and large open gears with
caveats and explanations for each type of appli-
cation.
CONTINUED ON PAGE 26
The hydraulic system, in a simplistic view, ac- is established by pump type and the specific
complishes work by squeezing a small quantity of pump’s efficiency parameters. If the fluid is too
oil into a pipe very rapidly and then directing the thick the pump may cavitate, overheat due to fluid
pressurized fluid through a set of valves to be re- friction, increase mechanical stress on bearing ele-
leased where specific mechanical force is needed. ments and consume excessive energy to fulfill its
There are several common components in a function. If the fluid is too thin the pump contact
hydraulic system, including: surfaces will wear and lose efficiency, and the
■ Reservoir. Provides a supply of oil to the pump may leak across internal and external seals
pump. and clearances and overheat.
System manufacturers offer a window for appro-
■ Pump. Adds flow/pressure to the oil.
priate viscosity performance. The equipment
■ Piping system. Contains the pressurized oil. owner must fit the product into the viscometric
■ Valve/control system. Channels energy in window. The following seven steps represent a sys-
the form of pressurized oil. tematic approach that may be used to arrive at the
■ Work components of some type. Performs best overall viscosity selection.
the required work. 1. Plot the operating temperature range for the
■ Filters. Protects critical components from system on a standard temperature-viscosity
catastrophic damage, cleans the oil. selection chart, as shown in Figure 14. The
These various components represent a mixture green lines represent high and low tempera-
of frictional properties, including rolling friction ture operating ranges. If the system hasn’t
(hydraulic motor and input motor bearings), sliding been commissioned, use the OEM’s suggest-
friction (pump vanes and pistons, hydraulic rods ed temperature profile.
and cylinders) and a combination of the two (gear 2. Hydraulic pump designers provide viscosity
pump tooth contacts, hydraulic motors). All these limits that include absolute maximum and
working components are sensitive to the physical, minimum limits (noted by the blue boxes)
chemical and cleanliness properties of the fluid. and optimum maximum and minimum limits.
Flow control systems tend to dictate fluid clean- Next, plot these provided values on the chart.
liness requirements. Cleanliness will be addressed Example: a pump manufacturer provides
in a future article. Pump type (mechanical inter- an absolute maximum limit of 1,000 cSt and a
face) and efficiency parameters typically dictate minimum of 10 cSt. These lines establish
physical viscosity parameters. Fluid type is dictat- finite limits for operating temperatures (cold
ed by plant environmental factors: basestock type start, high operating temperature limits) for
and additive performance selection. It is not the final fluid selection. Additionally, the
unusual for a given product selection to have con- OEM offers the ideal minimum (16 cSt) and
flicting priorities. ideal maximum viscosity (36 cSt) values. The
Despite the many differences between systems, gray lines on the chart represent viscosities
they are all intended to operate within an efficien- that support optimum volumetric efficiency.
cy range. The allowable viscosity for a given system 3. Find the intersecting lines between the oper-
ating temperature limits
(green lines) and optimum
Figure 14. Hydraulic oil viscosity selection chart viscosity limits (grey lines).
This cross-section repre-
sents the target space
through which we would
like our best product choice
(Courtesy of Advanced Machine Reliability Resources)
to pass.
4. Review and plot the vis-
cosity parameters for
each of the available
fluid choices on the vis-
cosity temperature chart.
Example: There are three
available options. Option
A is an ISO 68 mineral oil
with a VI of 100. Its default viscosity meas- the OEM might install a thermostatically-
urements are 64.6 cSt at 40 C, and 8.4 cSt at controlled heater to assure safe start condi-
100 C. These points are plotted and a line is tions. If the system happens to be installed in
drawn from the far left of the chart through outdoor construction machinery, then it is
these points to the far right of the chart. The likely that eventually this machine will have
extreme ends of this line represent tempera- to function below the cold start limit sug-
ture extremes that will be considered later. gested for fluid A, making it undesirable for
This process is repeated for the other avail- the application.
able products (options B and C are provided). 7. Repeat this evaluation process for each prod-
5. Evaluate the cold flow temperature limit for uct type until the best option is identified.
each of the plotted lines and eliminate any
that do not meet the limits for cold weather Industrial hydraulic applications
operation. As shown in Figure 15, several categories of hy-
Example: Identify the product that has the draulic fluids may be considered. Water-based flu-
longest line segment passing through the ids are preferred for applications where fire is a
optimum area (noted in Step 3). In this case CONTINUED ON PAGE 28
it appears to be option A. Observe the left
side of the chart where the ‘A’ line passes
through the OEM’s absolute low viscosity
limit. Line A crosses this (1,000 cSt) line at Compo
about 0 C. This temperature is the lowest unded
used in oils ar
possible temperature that the system can be
drives e
allowed to run with this fluid. If it is likely
high sl with
that the system will be expected to start at iding c
temperatures lower than 0 C, then another surface ontact
option must be considered. Repeat the steps pressur
for each additional product option. soft m es and
etal ge
6. Make the final selection based on the best fit as wit ars–su
for optimum viscosity within the operating h worm ch
temperature range and the least risk of cold type a gear
pplicat
start failure. ions.
Example: If the fluid is being selected for a
hydraulic system that is bolted to the floor, it
is unlikely that the cold start temperatures
will ever fall below 0 C. To control this risk,