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Friction:
observed
between
two
moving or sliding surfaces creating wear Lubricant: Any substance introduced between two
Functions of Lubricant
o To reduce frictional resistance between surfaces and
reduce deformation, wear and tear between moving/sliding surfaces. To reduce loss of energy in the form of heat (Coolant). To reduce waste of energy i.e., to increase efficiency of machines. To reduce irregular expansion of metals. To reduce welding of the two surfaces. To reduce or avoid rough relative motions of moving / sliding parts. To reduce running and maintenance cost of the machine. To reduce the leakage of gases under high pressure like a seal or Teflon.
o o
o o o o o
Mechanisms of Lubrication
1. Fluid-film (or) Thick-film (or) Hydrodynamic lubrication 2. Boundary lubrication (or) Thin-film lubrication 3. Extreme pressure lubrication
(~ 1000 )
Characteristics:
o The surfaces are separated by a thick-film (at least 1000 thick) and hence there is no direct surface to
surface contact.
o No welding of junctions. o Since thick film lubricant covers/fills the irregularities on the both surfaces, there is no direct contact between material surfaces and so the wear is reduced.
Lubricant oil covers the irregularities of the shaft as well as the bearing surfaces.
Graphite and Molybdenum disulphide alone or oil suspension may be used because:
o They have Low internal friction
o They can bear/withstand compression o They are thermally stable
3. Extreme-pressure Lubrication
When moving/sliding surfaces are under very high pressure and speed, a high local temperature is attained. In such conditions, liquid lubricants fail to stick and may decompose and even vaporize. To avoid this, special additives are added to mineral oils. These are called extreme-pressure additives.
Mechanism
The extreme-pressure additives form on metal surfaces more durable films, capable of withstanding very high loads and high temperatures. Examples: Organic compounds containing chlorine, sulphur and phosphorus.
o These compounds react with metallic surfaces, at prevailing high temperatures, to form metallic chlorides, sulphide or phosphides. o These metallic compounds possess high melting points.
CLASSIFICATION OF LUBRICANT
Based on Physical state, lubricants are classified as:
a) Lubricating oils or liquid lubricants
b) Semi solid lubricants or greases c) Solid lubricants
Liquid lubricants are most widely used lubricants because they are
1. Cheap 2. Available in abundance 3. Quite stable under service conditions.
f) Antioxidants or inhibitors : Aromatic phenolic or amino compounds g) Corrosion preventers : Phosphorous or Antimony organic compounds h) Abrasion inhibitors i) Antifoaming agents j) Emulsifiers : tricresyl phosphate : glycols and glycerol : sodium salts of sulphonic acid
k) Deposit inhibitors
Applications of Greases:
o When oil cannot remain in place due to high load, low speed, intermittent operation, sudden jerks etc. o Work at high temperature o When external contamination may create problem o When dripping or spurting of oil is undesirable
Types of greases:
o
o o o o o
Calcium based greases or cup-greases Soda-based greases Lithium-based greases Axle- greases lime with resin and fatty acids Graphite greases Soap stone
3. SOLID LUBRICANTS
Solid lubricants are used when:
o Other lubricants can not be used
o Contamination undesirable o Too high temperature or load are involved o Combustible lubricants not acceptable
Properties of Lubricants
1. Viscosity: The property of a liquid or fluid by virtue of which it offers resistance to its own flow . - Viscosity should not be too low or too high.
Flash Point:
The lowest temperature at which the oil lubricant gives off enough vapour that ignites for a moment, when a tiny flame is brought near it. Fire Point: The lowest temperature at which the vapour of the oil burn continuously for at least five seconds, when a tiny flame is brought near it.
3. Oiliness: A measure of its capacity to stick on to the surfaces of machine parts under conditions of heavy pressure or load.
o For high pressure
5. Volatility:
o Good lubricant should have low volatility.
o It is measured by vaporimeter.
6. Emulsification:
o The property of oils to get intimately mixed with water forming
an emulsion. o Emulsions have a tendency to collect dirt, girt, foreign material etc., causing abrasion and wearing out of the lubricating parts of the machinery. o A good lubricating oil should form an emulsion with water which breaks off quickly.
7. Carbon residue:
Normally lubricants consist of high % of carbon containing compounds.
o Lubricants decompose due to raise in temp. and deposit
8. Corrosion stability:
Corrosion Test: o A polished copper strip is placed inside a lubricating oil for a specified time and temperature and then checked for any tarnishing . o To prevent or retard corrosion effect of lubricating oils, additives such as Phosphorous, Arsenic, Antimony, Chromium, Bismuth or Lead are added.
9. Decomposition stability:
o Lubricating oils must be stable to decomposition at the operating temperatures by :
abrasion and wear it may cause 14. Saponification number: o Number of milligrams of KOH required to saponify 1g of oil.
16. Neutralization Number: o Is a scale to determine the amount of acidic or basic constituents of an oil. o Acid Number: Amount of KOH required in milligrams to neutralize the fatty acids in 1g of oil. o Good lubricating oil acid number value < 0.1