CHAPTER 5 LUBRICANTS AND LUBRICATION

LUBRICANTS In order to reduce metal to metal contact and to reduce the frictional force and heat generation, certain foreign substances are introduced between the rubbing surfaces which keep them apart .These substances are called lubricants. LUBRICATION The process to reduce frictional force between the sliding and rubbing surfaces of metals is called lubrication. FUNCTION OF LUBRICANTS The important functions of lubricants are as follow. It reduces wear and tear of the surfaces by avoiding direct metal to metal contact between the rubbing surfaces, i.e. by introducing lubricants between the two surfaces. It reduces expansion of metal due to frictional heat and destruction of material. It acts as coolant of metal due to heat transfer media. It avoids unsmooth relative motion. It reduces maintenance cost. It also reduces power loss in internal combustion engines. TYPES OF LUBRICATION (1) Fluidfilm lubrication (2) Boundary lubrication (1) FluidFilm Lubrication

This type of lubrication is used when two surfaces of the materials rotate against each other while being completely separated. The liquid lubricants form a very thin film between the moving surfaces and thus avoid the direct metal to metal contact and reduce friction. This condition is known as fluid film lubrication. The resistance to movement of sliding moving parts is only due to the internal resistance between the particles of the lubricants moving over each other. Therefore lubricant chosen should have the minimum viscosity under working conditions and at the same time, it should remain in place and separate the surfaces.
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Delicate machines and light instruments like watches, clocks, guns, sewing machines, scientific instruments etc. are provided with thick fluid film lubrication. (2) Boundry Lubrication

Boundary lubrication may happen slide or rotate against one another under heavy load, and such conditions there may be contact between the moving surfaces and film breaks down under these conditions, an oil is used which interact with the solid surface of the metal that will between the two sliding surfaces. This can be possible by adsorption of lubricant molecules on the surfaces or by chemical reaction of the lubrication substances with metal surfaces. CLASSIFICATION OF LUBRICANTS (1) Solid lubricants Solid lubricants are used for railway tract joints, chains, air compressors, open gears, heavy machines etc. the examples of solid lubricants are wax, talc, mica, molybdenum disulphide graphite etc. (2) Semi solid lubricants It is used where the machine parts are subjected to slow speed, heavy load & sudden jerks. The examples of semi solid lubricants are grease & Vaseline. (3) Liquid lubricants Liquid lubricants are used in delicate and light machines which work at high speed but under low pressure. Mineral oils, vegetable oils & animal oils are the various types of liquid lubricants. (4) Synthetic lubricants It can be used, where extreme temperature, chemical reactive atmosphere or some very particular operating conditions are involved & where all other lubricants fail to work effectively. e.g. polyglycols, silicones, organic amines, imines & amides. TEST OF LUBRICANTS AND THEIR SIGNIFICANCE

Viscosity
The resistance to flow of liquid is known as viscosity. The unit of viscosity is poise. OR the force in dyne, required to move one square centimetre layer of the liquid with a velocity 1 cm/sec. to another parallel layer of the liquid.

Viscosity Index : The rate of change of viscosity with change in temperature is called viscosity index. A good lubricant is one whose viscosity does not change much with change in temperature. Oilness The power of an oil to maintain a continuous film under pressure while it is used as lubricants. A lubricant which does not squeeze out from the sliding surface & maintain a continuous film is known as lubricant having high degree of oiliness. Volatility Volatility of a lubricant is its tendency to vaporise with the increase of temperature. If the lubricant is highly volatile, it will vaporise readily even at low temperature. A good lubricant should have low volatility. Flash Point The minimum temperature at which a lubricant gives momentary flash of light when a flame is applied to it, but it does not continue to burn. Lubricants with higher flash point are preferred. Fire Point The temperature at which a lubricant catches fire and burns continuously when the flame is applied to it. Fire point of oil is always greater than its flash point. Pour Point It is the lowest temperature at which the oil ceased to flow when cooled under prescribed conditions. If oil is used at a temperature below the pour point, the lubrication action will stop. Cloud Point The cloud point of lubricating oil is the temperature at which cloudiness develops due to separation of wax on cooling. Neutralization Number or Acid Value It is defined as The number of milligrams of KOH required to neutalise one gram of the oil. Saponification Number It is defined as the number of milligram of KOH required to saponify one gram of oil or fats. Emulsification When oil is mixed with water or water is mixed with oil, emulsion is formed. A good lubricant is one which does not form emulsion and even if it forms, the emulsion should break quickly. Copper strip test for Corrosion In this test, a smooth and polished copper strip is immersed in the lubricating oil for a particular length of time at a specific temperature. Copper strip is taken out after specified time. If some pitting or furnished spots are observed, it means the lubricating oil contain some corrosive material. The presence of corrosive material reduces the quality of lubricants.

Carbon Residue Test The deposition of carbon by a lubricating oil, when it is subjected to heat under working conditions is called carbon residue test.Deposition of carbon is harmful. ADDITIVES USED IN LUBRICANTS (1) (2) (3) (4) Anti oxidant --- Aromatic amines,Phenols,Sulphides and phosphates Corrosion Inhibitor --- Amino salts and salts of sulphonic acids Antiwear agents --- Tricresyl phosphate Foam inhibitors --- Glycerols

Selection of lubricants for Gears The gears are generally subjected to high pressures so, it must have following properties. (1) It should possess good oiliness. (2) It should not be removed by centrifugal force from the place of application. (3) It should be highly resistant to oxidation. (4) It should have high load carrying capacity. Selection of lubricants for Cutting Tools Cutting metal tools when used for performing any machining operating such as cutting sawing, turning, boring, drilling etc. required the use of certain oil known as cutting oils must have following properties. (1) The oil must have both lubricating and cooling properties. (2) It should be chemically stable. (3) It should have high conductance to thermal Selection of lubricants for Steam Turbines In steam turbines, lubricating oil is exposed to high temperature and oxidizing conditions hands it should have following properties. (1) It should have emulsification properties. (2) It should have antifoaming properties. (3) It should have corrosion resistance properties. (4) It should have high oxidation properties.

Question asked in T.E.B. exam

Q.1 Q.2 Q.3 Q.4 Q.5 Q.6 Q.7 Q.8 Q.9 Explain boundary lubrication. (with diagram). Classify lubricants with examples. Explain liquid lubricants in detail. Define flash point & fire point, viscosity, saponification number. Define drop point of grease. What type of lubricants you will select for cutting tools ? What is importance of copper strip test of a lubricant ? Write primary aims of lubrication. Which type of lubricants will you select for gears ? Explain fluid film lubrication.

Q.10 Write at least five functions of lubricants. Q.11 What property would you consider while selecting lubricants for the use in steam turbines.