Gear Lubrication & MAK GRADES
FUNCTION OF A GEAR
Power Transmission
Change in Direction
Change in Speed
Change in Torque
OPERATING OPERA TING CONDITION CONDI TION
The gears of the drive are subjected to: o
Continuous heavy loads associated with frequent shock loads or fluctuating loads.
o
High-speed operations for new generation equipment.
o
Hostile working environment like temperature/dust/fumes.
DIFFERENT TYPES OF GEARS
GEAR SYSTEMS Enclosed Gear Syste Systems ms reduce lubricant loss and are smaller in size
Open Gear syste systems ms are generally large and slow speed. Higher load requires higher viscosity • The oil must be viscous & prevent oil loss • Ensure no channeling takes place •
•
Higher speed required lower viscosity
•
The oil must be thinner to save power consumption
FUNCTIONAL REQUIREMENT Viscosity for 1. Correct Viscosity for formation of film of proper thickness. 2. Anti-wear Anti-wear & & Extreme Pressure properties. 3. Good Oxidation stability to minimise oxidation under adverse conditions of heat and presence of air. 4. Good Anti-rust property to protect gears from rust in presence of moisture. 5. Resistance to Foaming Foaming.. 6. Adequate low temperature fluidity to prevent Channeling.
TYPES OF GEAR LUBRICATION LUBRICATION
Grease Splash Spray
Lubrication Lubrication
Lubrication
Forced
Lubrication
TYPES OF LUBRICATION 1) Grease Lubrication •
•
•
Suitable for any gear system that is open or enclosed Not suitable for high loads and continuous operation and there is virtually no cooling effect 0 to 6 m/s tangential gear speed
TYPES OF LUBRICATION 2. Splash Lubrication •
•
•
•
Used with an enclosed system Rotating gears splash lubricant onto the gear system and bearings Needs at least 3 m/s tangential speed to be effective 4 to 15 m/s tangential gear speed
… ..
TYPES OF LUBRICATION
….
An oil pump is used to suck-up the lubricant and then directly drop it on the contact portion of the gears via a delivery pipe
•
Drop Method:
3. ForcedCirculation Lubrication
Spray Method
Lubricant is mixed with compressed air to form an oil mist that is sprayed against the contact region of the gears. It is especially suitable for high-speed gearing.
•
Oil Mist Method
An oil pump is used to spray the lubricant directly on the contact area of the gears
•
INDUSTRIAL GEAR OILS - STRUCTURE
LUBRICANT SELECTION Factors influencing selection of gear lubricant, # Gear Type # Gear Speed # Reduction ratio # Operati Operating ng Temp. # Power Transmi ransmitted tted
EFFECT OF SPEED & LOAD ON LUBRICANT SELECTION
GEAR OIL TYPES STRAIGHT MINERAL OILS • mild
operations • good oxidation stability
R & O Inhibited TYPE • moderate loads • Right
Most Widely Used
balance of Antiwear additives • Good resistance against rusting and oxidation
EXTREME PRESSURE TYPE • contain
sulphur / phosphorous additives for extreme pressure • suitable for any gear box operating at heavy loads
ANTI MICROPITTING TYPE • Severe
and shock loads • energy efficient • higher load bearing capacity
COMPOUNDED TYPE • especially
for Worm gears
MAK GEAR OILS GEAR OIL – EP Type GRADE: RANGE:
MAK Amocam ISO VG 46, 68, 100, 150, 220, 320, 460, 680, 1000
PERFORMANCE LEVEL: US Steel 224, DIN 51517 Part 3, IPSS
AGMA 250 & 251, David Brown S.1.53.101 IS 8406 (EP Type) Features Excellent Oxidation and Thermal stability Antiwear and EP Characteristics Good Antiwear Smother operation at Higher Temp. Good Anti-foam Characteristics
MICRO-PITTING IN GEARS •
•
•
Surface Degradation at micro level Approximately 10-20 depth
μm in
Micro pitted metal often has a frosted or gray appearance
MICROPITTING Today's industrial gearboxes operate with higher power densities, reduced oil volumes and increased temperatures-all of which put further stress on gear teeth. And hence evolved a serious problem, named as MICROPITTING.
Micropitting is a surface fatigue phenomenon Approximately 10-20
μm in
depth pits on surface
Micro pitted metal often has a frosted or gray appearance Amplified by Shock loads Anti micro pitting gear oil is required to avoid micro pitting These oils should be Flender Fl ender AG AG micropitting performance requirement FZG FV F VA 54 test.
MAK GEAR OILS GEAR OIL – Anti-Micro Pitting GRADE: RANGE:
MAK Amocam Plus ISO VG 100, 150, 220, 320, 460, 680, 1000
PERFORMANCE LEVEL: US Steel 224, DIN 51517 Part 3, IPSS
AGMA 250.04 & 02, David Brown S.1.53.101 Micro Pitting Performance Features Potential for Energy saving Contains Friction Modifiers Excellent Oxidation and Thermal stability Excellent anti Micro-pitting Performance. Performance. Extended Drain Interval
–
Flender AG AG
COMPARISON CONVENTIONAL OIL VS COMPARISON ENERGY EFFICIENT OIL Characteristics Char acteristics
Method
Type / VG
Amocam 320
Amocam Plus 320
Mineral / 320
Mineral / 320
Timken Timken OK Load (lbs)
D 2782
65
80
4 Ball Wear Wear in mm
D 4172
0.36
0.33
FZG Load Test
D 5182
12
12+
Flender FZG Micro pitting Test
FVA FVA 54
NA
10+
Pass
Pass
Oxidation Stability
•
Overall energy saving up to 1-2%
TRIAL RESULTS, Customer : Bhushan Steel Equipment : Uncoiler of Trimmer Machine Tasted Against : Shell Omala 320 Overall Energy Saving : Upto 4.5%
MAK GEAR OILS GEAR OILS – STRAIGHT MINERAL OIL TYPE MAK CABOL ISO VG : 100, 150, 220, 320 & 460
Performance Level: IS 493 (Part 1):1981
Salient Feat Features: ures: Highly refined straight mineral oil Mildly loaded enclosed gears where additive type oils are not required
MAK GEAR OILS GEAR OIL – R & O Inhibitor Type GRADE: RANGE:
MAK Hydrol (Gear Oil) ISO VG 220, 320, 460
PERFORMANCE LEVEL: IS 3098 : 1983, IS 10522 : 1983 DIN 51524 51 524 Part I HL Type Type IPSS : 1-09-022 Features Property perty Excellent Anti-wear Pro Good Oxidation Stability Suitable for Mildly loaded Gearbox Suitable for Worm Gear Lubrication
MAK GEAR OILS GEAR OIL – Compounded Type GRADE: RANGE:
MAK Engol J ISO VG 460, 680, 1000, 1500
PERFORMANCE LEVEL: IS 1589 : 1994 Type 2 IPSS : 1-09-010
Features Excellent wet-ability Possesses Excellent Film Strength Suitable for Worm Gear Lubrication
MAK GEAR OILS GEAR OIL – SYNTHETIC TYPE GRADE: RANGE:
MAK Syngear ISO VG 220, 320, 460, 680, 1000
PERFORMANCE LEVEL: US Steel 224, DIN 51517 Part 3
AGMA 9005-E-02, David Brown S 1.53.101 (E) Micro Pitting Performance
–
Features Extended Life Excellent Oxidation and Thermal stability (VI ~ 160) Anti Micro-pitting performance. Excellent Anti Good Low Temp Properties Approved by Flender & MAAG Gear
Flender AG AG