TLT dEC 2013 PDF

TLT
SYSTEMS, STRATEGIES & RESEARCH FOR LUBRICATION PROFESSIONALS AN PUBLICATION | DECEMBER 2013
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
10 YEARS
of publishing excellence
Lubrication
Fundamentals
Whether you’re new
to the world of fluids
management or an
industry veteran,
there’s something
of interest for you in
this 36-page special
section from STLE.
69th STLE
Annual Meeting & Exhibition
May 18-22, 2014
Disney’s Contemporary Resort
Lake Buena Vista, Florida (USA)
Technical and professional development you can’t get anywhere else!
When it comes to advancing

your career and upgrading your
technical knowledge, STLE’s
Annual Meeting & Exhibition is
a unique event in the lubricants
industry. 1,200 of your peers in the
lubricants community are expected
to participate in STLE’s 69th Annual
Meeting & Exhibition. Please join
us in Lake Buena Vista for a unique
experience that blends the best
of industry education, technical
training, professional certification
and new technologies.
• 400 Technical Presentations

• 12 Industry-specific Education
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Society of Tribologists and Lubrication Engineers

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Contents
3 Viscosity: A fluid’s resistance to flow
3
New to the world of lubricants? Here’s more
about rheology than you ever wanted to know.
6 The basics of viscosity index

There are many factors to calculating the
6
viscosity of a lubricant. But understanding
its temperature in cold and hot environments
8
is the first step.
8 The mysterious world of lubricant additives

This handy primer is your guide to these
multifunctional and all-important chemicals.
12 Consistently consistent grease

Several tests help us ensure that what we
12
want is what we get—all the time.
15 The global case for green

Good intentions aren’t enough. You must
get all parts of your operation working in
15
environmental harmony.
18 Bearings and their lubrication

This primer will help you understand the
basics—and prepare for the CLS exam.
18
22
22 The basics of filters and filtration
Establishing a good relationship with your
supplier is the best strategy to using these
materials successfully.
24
24 The mysterious world of seals
These important structures play a major
role in making sure a lubricant stays in place.
26 Turbines: What goes around comes around

There are three main types of
turbomachinery, and each has its own
set of lubrication requirements.
26
29 What’s a gear?
An overview of the machine elements
that keep the industrial world turning. 29
W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY 1
FROM THE EDITOR
Evan Zabawski
Lubrication Fundamentals:
A TLT special section
Regardless of where you are now in your Before joining the STLE headquar-
career, all of us who earn a living ters staff in 1998, Bob was a 20-year
through tribology or lubrication engi- member where, among his many vol-
neering started in the same place. With unteer activities, he chaired the Solid
the basics. Lubricants Technical Committee and
If it’s true that you can’t run until Aerospace Industry Council. He
you can walk, then neither can you gained an understanding of the soci-
make decisions about lubricants with- ety’s governance structure as a board
out knowing what viscosity means. member, where he served as treasurer
Education has always been one of and secretary.
STLE’s primary missions, and while Bob’s columns on Lubrication Fun-
the delivery methods have changed damentals have been an integral part
since 1944 when the society was of TLT since the magazine was
founded, our commitment to techni- launched in 2003. For this special sec-
cal training has never been stronger. Bob Gresham spent 20 years as an tion, we’ve pulled 10 essays that span a
Each year hundreds of STLE mem- STLE member before joining the society’s fairly broad range of topics. In addi-
bers help educate their peers by writ- headquarters staff in 1988. tion, be sure to check out the first is-
ing papers, teaching courses at the an- sue of our new Lubrication Funda-
nual meeting, conducting seminars mentals technical e-newsletter for
and making presentations at local sec- velop their professional skills. additional topic articles (available at
tion meetings. While Bob has a hand in almost ev- www.stle.org).
While this truly is a win-win sce- ery area of member service, certainly Even though I’ve logged a few years
nario for all involved, coordinating all his most visible role is writing TLT’s of experience in this field myself, I re-
those activities is a Herculean task. For monthly Lubrication Fundamentals ally enjoyed and benefited from re-
a decade now, the job has rested column. Since Bob is the modest type, reading these articles. Whether you’re
squarely on the shoulders of Dr. Rob- please allow me a moment to tell you a an industry novice or a veteran, I be-
ert M. Gresham, STLE’s director of little more about the man behind the lieve you’ll have the same experience.
professional development and the au- keyboard. Bob writes with style that is both infor-
thor of this special section on lubrica- After receiving his doctorate in or- mative and engaging.
tion fundamentals. ganic chemistry from Emory Univer- Let the education begin.
If you’ve been an STLE member for sity in Atlanta, Bob spent 12 years in
even a few years, you’ve probably ei- several manufacturing and customer
ther met Bob or benefited from his ef- service positions with the DuPont Co.
forts. If you’ve been fortunate to spend He gained an additional 17 years of in- Evan Zabawski, CLS, is a
time with him, you know Bob is an dustry experience as vice president of reliability specialist in
intelligent, focused individual with a technology with E/M Corp., a manu- Calgary, Alberta, Canada.
lively sense of humor and a deep com- facturer and applicator of solid film You can reach him at evan.
mitment to helping STLE members de- lubricants. [email protected].
2 T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG
LUBRICATION FUNDAMENTALS
Editor’s Note: This article was prepared in collaboration with
STLE-member Dr. Philip Guichelaar, Western Michigan University.
Viscosity:
A fluid’s resistance
to flow
New to the world of lubricants? Here’s more
about rheology than you ever wanted to know.
I HAVEN’T WRITTEN ABOUT VISCOSITY in needed to rotate the spindle). Then we

a long time, but it’s a topic always make a plot of the shear stress and
worth revisiting. We frequently say shear rate, as shown in Figure 1. Ide-
that viscosity is the most important ally the data would fit a straight line
property of fluid lubricants. Recall that starting from zero. The slope of that
viscosity is equal to the shear stress/ line (or its steepness) is the viscosity
shear rate. That’s kind of abstract, so for that oil or test material at the tem-
just think of it as the resistance to flow. perature of measurement.
We can all think of thick and thin
fluids, like water, syrup and the like,
and that’s kind of an obvious macro Flow Curve
look at viscosity. What happens if we
stir a can of oil at different speeds?
Does it seem obvious that more effort
is required to stir at a faster speed?
What about other materials, like
Shear Stress
paint? More effort is required, but for

some oils or other materials it is not
proportionally more effort.
We can determine the effect of stir-
ring rate with a rotary viscometer by Shear Rate
rotating the spindle at different speeds.
For each of these speeds, we calculate Figure 1 | The correlation between shear
the shear rate (related to the rotation stress and shear rate defining the flow be-
speed of the spindle) and measure the havior of a liquid is graphically displayed.
shear stress (related to the torque This diagram is called a flow curve.
An equipment design engineer designing a bearing, gearbox or a lubricant dispensing
device needs to understand the implications of rheology on the design.
this quirky viscosity behavior, with the valuable les-

son that slow escape movements consume less energy
than violent movements against an instantly thick
Tangential Stress (F/A)
μ
morass.
Shear Stress • Bingham Plastic Fluids. The viscosity curve for Bingham
Viscosity = ______________ 1 plastic fluids does not go through the origin. As shown
Shear Rate
in Figure 5, the shear stress can be substantial even at
a small shear rate, but once the fluid moves the shear
stress is directly proportional to shear rate in exactly
the same manner as for Newtonian fluids. Water sus-
Rate of Shear (dv/dy) pensions of rock particles behave in this manner. More
familiarly, mashed potatoes, a suspension of tasty sol-
ids in a liquid, flow in the bowl when you stir, flow
Figure 2 | Newtonian behavior
harder when you stir harder and assume a mountain
peak shape if undisturbed.
Remember that mathematically and also graphically, an • Shear Time Dependent Fluids. For these fluids, the shear
oil whose viscosity remains constant as we increase or de- stress changes with time of shearing. This behavior is
crease the shear rate is a perfect fluid, which is depicted in related to breaking bonds between particles or mole-
Figure 2. The term Newtonian is used to designate this be- cules or to changes from the at-rest shape of long mol-
havior. Water, gasoline and most unmodified mineral oils ecules.
display very nearly Newtonian viscosity curves.
Most fluids, including motor oils, are not perfect or New- • Thixotropic Fluids. Fluids that are thixotropic are not
tonian. The shear stress is not directly proportional to the simply small molecules aggregated together such as
applied shear rate such that when the shear stress is plotted water. They include molecules that have a longer
against the shear rate, the points are not in a straight line. range structure that can be altered with mechanical
Often, the points do not begin from zero shear stress and shearing. For most of these fluids, the viscosity de-
zero shear rate. creases at higher shearing rates, as shown in Figure 6.
Certain other fluids are sensitive to the length of time that Mayonnaise has this characteristic. It is not a Bingham
the fluid is being sheared, resulting in changes in viscosity plastic fluid because its viscosity decreases with high-
with the duration of the experiment. These kinds of fluids er rates of shearing—but only after a minimum
have interesting names: amount of shear is reached. Yogurt (without the tasty
fruit addition) also is reputed to have this behavior.
• Pseudoplastic Fluids. The viscosity of pseudoplastic Finally, good quality wall paint and motor oils are
(and plastic) fluids decreases with increased shearing, carefully compounded to be thixotropic. Can you ex-
as shown in Figure 3. Molten polymers have this char- plain why users of these fluids would be pleased to
acteristic, which is used to advantage in injection have thixotropic behavior?
molding when the material flows through small cross
section gates. Paper pulp suspensions also display • Rheopectic Fluids. This behavior is not common or very
pseudoplastic viscosity behavior. useful because the viscosity increases with additional
shearing after the minimum amount of shear is exert-
• Dilatant Fluids. For these fluids, the viscosity increases ed. Some clay solutions in water behave in this man-
with increased shearing, as shown in Figure 4. A mix- ner. Can you imagine the behavior of rheopectic
ture of water and cornstarch can have the consistency paint? It thickens into clumps when you apply it, and
of thick cream if it is poured slowly but will form a when you stop trying to smooth it out, it runs down
thick paste if it is stirred briskly. Quicksand also has the wall.
the fluid rapidly becomes thicker or
more viscous.
Paint is usually compounded to be
thixotropic. It applies easily (high
shear stress and rate) but it doesn’t sag

or run when the brush is removed, yet
has time to flow and level out before
thickening. At low temperatures, wax
particles in lubricating oils can cause
the non-Newtonian thixotropic behav-
ior of the oil to become even more pro-
nounced.
How does a pseudoplastic oil be-
Rate of Shear (dv/dy) Rate of Shear (dv/dy)
have in a hydrodynamic bearing? At
Viscosity Decreases Viscosity Increases startup, the shear rate is slow and the
with Rate of Shear with Rate of Shear oil has a high viscosity such that the
transition to mixed lubrication is fa-
cilitated. As the shaft speeds up, the
viscosity decreases, but the hope is
Figure 3 | Pseudoplastic Flow Figure 4 | Dilatant Flow that the increased speed compensates
and the system remains in the mixed
lubrication regime or transitions into
the hydrodynamic regime. On the oth-
er hand, with a thixotropic fluid, at
startup if the shear rate is slow the oil
initially supports the bearing. If the
shear rate remains constant, the oil
will eventually thin and not support

the bearing.
A dilatant fluid is the opposite of a
pseudoplastic fluid in that its viscosity
increases with shear rate. This would
be very bad for a paint system, as
spreading the paint evenly would be
Rate of Shear (dv/dy) Rate of Shear (dv/dy) very difficult. If a lubricating oil was
dilatant, its viscosity would increase
Thixotropic: Decrease with speed and friction losses would
Viscosity with Time increase, not a good outcome when
the general objective is to decrease en-
ergy consumption.
Figure 5 | Pseudoplastic Flow Figure 6 | Dilatant Flow Clearly, viscosity and rheology are
important to the proper operation of
mechanical equipment. An equipment
The non-Newtonian fluids discussed before have impor- design engineer designing a bearing, gearbox or a lubricant
tant behaviors. For example, in pseudoplastic fluids, flow dispensing device needs to understand the implications of
does not begin until a minimum shear stress level is reached. rheology on the design. If we know the conditions under
This is important for printing ink rheology where we would which the “converging wedge” is operating, the rotating
not like the ink to move until it is deposited on paper. speed, the load and the possibility of any intermittent chang-
Once the minimum shear stress has been reached, the es in pressure with time, and if we can predict the range of
fluid thins with increasing shear rate and penetrates the operating temperatures, we can specify a viscosity and vis-
structure of the paper. When the shear stress goes back to cosity index for effective lubrication. Conversely, if we know
zero, the ink does not move. the viscosity profile of a lubricant, we can design a mechani-
Similarly with thixotropic fluids, flow can vary with ap- cal system to operate reliably.
plied shear stress and/or rate, becoming rapidly thin with Lubricant formulators must keep all of these concepts in
increasing shear time. But when shear forces are removed, mind and under control when developing new products.
The basics of viscosity index

There are many factors to calculating the viscosity of a lubricant.
But understanding its temperature in cold and
hot environments is the first step.
AS HAS BEEN SAID MANY TIMES in several articles published in TLT, viscosity is the
most important property of a lubricant. And so it is important to understand the
concepts fully. In this article, we’ll take a look at viscosity index (VI).
VI is a means of expressing the lubricant’s variation in viscosity with respect to
temperature (see Figure 1). In general, this means the viscosity increases with cold
and decreases with heat. Each machine is designed with an optimum lubricant
viscosity range to insure sufficient film thickness to reduce friction and prevent
wear. Clearly, the less a lubricant varies with temperature, the more a lubricant can
be used in cold as well as hotter environments.
Viscosity versus Temperature
Figure 1 | A lubricant’s variation in viscosity with respect to temperature.
This cuts two ways. When a lubricant is too cold (not up

to operating temperature), either because of the environ- VI = 100 X (L – U) / (L – H)
ment, as in winter, or just because we are just starting up a
machine, the viscosity is too high, the lubricant doesn’t flow This is pretty exciting stuff, right? Perhaps the example
well and wear can ensue. Equally, if the lubricant is too hot below will help. For an oil of 10.0 centistokes (cSt) viscosity
because of the environment or because we are overworking a at 100 C, the table in ASTM D2270 provides L= 147.7 and H
machine, the viscosity is too low, and we don’t have sufficient = 82.87. If the test oil has a 40 C viscosity of 110 cSt, it would
film thickness to prevent wear. have a VI of 58 using the formula below:
So if this is important, how do we determine the VI of a
lubricant? VI is calculated from the measured viscosity at 40 C VI = 100 X (147.7 – 110) / (147.7 – 82.87) = 58
and 100 C using ASTM D2270. Unfortunately, the method is
a wee bit awkward and arcane, yet widely used. Its utility is If this isn’t painful, awkward and arcane enough, if the VI
in characterizing base oils or finished lubricants and cannot is over 100, as many mineral oils and synthetics now are, we
be used as blending guidance (i.e., blending two oils 50-50, have to go to a completely different calculation. As of now,
which have VIs of 80 and 100 don’t necessarily provide oil when dealing with VIs of 100 or more, U, the viscosity of the
with a VI of 90). test oil at 40 C, is less than H. For these oils, VI is defined by
The idea of the method is to measure the viscosity of a a new parameter, N, calculated from Y and H rather than H
test oil at 100 C (called Y). Then, consulting a huge chart in and L as before. Thus, a new formula is shown below:
the ASTM method and using the measured viscosity of the
test oil, the tester looks up values for two parameters called VI = 100 + 140 X ((antilog N) – 1), where
L and H. L is the 40 C viscosity of some mythical oil having
the same viscosity of our test oil at 100 C, defined as having N = (log H – log U) / log Y)
a VI of 0. H is also the 40 C viscosity of another mythical oil
having the same viscosity of our test oil at 100 C but defined We’re having fun now! So what’s a poor soul to do?
as having a VI of 100. High VI is defined as having less varia- Probably the easiest and fastest thing to do is to call your
tion with respect to temperature; thus L is larger than H. The supplier. Second, grind it out with ASTM D2270, ugh. Fi-
VI of the test oil is defined by the relationship of its 40 C nally, you might find a computer program that will calculate
viscosity (called U) to the parameters L and H. Thus, the VI it all for you.
of the test oil becomes the percent of the way U is from L to The point of all this is that viscosity index is an important
H, as shown in the following formula: parameter in characterizing base oils and lubricants.
Dr. Robert M. Gresham / Contributing Editor
The mysterious
G 8
This handy primer is your guide to these
multifunctional and all-important chemicals.
enerally in most applications, lubricants must clean by washing away wear de-
bris or metal chips in metalworking operations, cool by removing heat from
machine or machining surfaces, lubricate by separating moving surfaces and seal
by filling voids and gaps in surfaces.
Lube 101 tells us that oil viscosity is one of the most impor-
tant properties of lubricants. Likewise, the chemistry of the oil
(synthetics, Group I, II or III mineral oils, etc.) is critical for the
intended application. But once the formulator identifies the right
oil for the application, the properties of the oil are augmented by
lubricant additives.
Lubricant additives are used in metalworking fluids, oils and
greases. Often the additives are dissolved or dispersed in a medium
that makes it easier to use in its intended application such as a wa-
ter or oil-based MWF, engine oil or grease. Aside from the thicken-
ers in greases, additives generally perform the same functions in
greases and oils. In MWFs, many of these same additives are also
used for these same purposes.
But in MWFs, additional additives also must be present to per-
form yet even more tasks. MWFs must promote tool life by remov-
ing heat, cooling, (because, just as with oils and greases, heat kills),
lubricate the interface between the tool and work piece, clean by
carrying chips away and preventing in-process corrosion.
T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG
world of lubricant additives
These are the macro issues. How-

ever, embedded in these functions are
events that need to be prevented, in-
cluding: Upper Surface
• poor surface finish Lubricant
Boundary
• chemical attack on Asperity Contacts Layers
the work piece
• mechanical damage Lower Surface
to the work piece
• metallurgical change
to the work piece
• thermal damage
Speaking as a chemist, whether it • water conditioners/soften-
• electrical changes to be grease or oil but especially with a ers (chelating agents)
the work piece. MWF, these issues pose a formidable • antimisting
set of interrelated and interacting
• antimicrobial pesticide
But these are just the operational problems. How do chemists balance
parts. Additionally, MWFs can con- all these different issues? Aside from • antifoam additives
tribute to a number of negative things, choices of base fluid material, they use and defoamers
all of which must be minimized: a mystifying array of additives. • dyes.
First, what do we mean by addi-
• mist leading to respi- tives? Additives are a chemical com- That’s quite a list! Thus, it is easy
ratory problems ponent or blend used at a specific treat to see why chemists look for additives
• dermatitis rate to provide one or more functions that can be multifunctional and why
in the fluid. Ideally, additive compo- with so many different chemicals in
• fungal and microbial growth. nents are multifunctional and gener- a formulation, additive compatibility,
ally used at treat rates from < 1 to 35 both with other additives as well as
All of these can lead to employee percent. They are soluble in mineral the base fluid, is of critical importance.
health and safety issues, plug filters oil, water or both in some cases. Are you mystified yet? Let’s take a
and cause other operational problems. Second, additives provide or assist very quick look at the most common
in a wide variety of functions: of the performance-related additive
types.
• boundary lubricity Boundary Lubricity Additives en-
• extreme pressure (EP) hance the lubricity of the fluid by ad-
sorbing on the surface of the metal to
• corrosion inhibitors form a film, reducing metal-to-metal
• reserve alkalinity boosters contact. These additives typically have
a polar group that interfaces with met-
• metal deactivators
al and tail that is compatible with min-
• emulsifiers eral oil or water. Examples are lard oil
The properties of the oil are
• couplers and canola oil. Solid lubricants also
augmented by lubricant additives.
are used for boundary lubrication.
Solid
Surface
Extreme Pressure Additives are a spe- form in two ways by either forming a (such as copper and brass) and reduce
cial type of boundary lubricity additive protective coating on the metal surface corrosion when dissimilar metals con-
that actually reacts with the metal sur- (as shown in the graphic below) or by tact each other. They act by forming
face, instead of adsorbing on the sur- neutralizing corrosive contaminants in a protective coating on the metal sur-
face, to form a metal salt layer between the fluid. Examples are overbased sul- face. Examples are mercaptobenzothi-
mating surfaces that reduces friction, fonates (we saw where some of these
wear and damage. In metalworking, also can act as extreme pressure addi-
the layer is between the tool and the tives), alkanolamides, aminoborates
work piece. and aminocarboxylates. It is important to have
These different additives have dif- Reserve Alkalinity Additives main- a good working relationship
ferent temperatures of activation. tain the fluid’s corrosion protection by
Thus, the chemist also chooses the neutralizing acidic contaminants and with top suppliers of
additive according to the application by maintaining the pH in a suitable lubricants, MWFs and
conditions so that the additive is, in range, essentially a buffer. These addi-
fact, activated at operating tempera- tives also can act as form emulsifiers additives.
tures. Examples of the various chem- with other components to stabilize the
istries are ZDDP, chlorinated paraffins, fluid. Examples are alkanolamines like
sulfurized lard oils, phosphate esters monoethanolamine (MEA), trietha- azole, tolyltriazole and benzotriazole.
and overbased calcium sulfonates. nolamine (TEA), aminomethylpro- Detergents stabilize dirt and wear
Corrosion Inhibitors prevent the fluid panol (AMP) and 2-(2-aminoethoxy) debris in oil formulations. Emulsifiers
from corroding the machine surfaces, ethanol. stabilize oil-soluble additives in water-
metal work piece, cutting tool and ma- Metal Deactivators prevent the dilutable MWFs by reducing interfacial
chine tool. Corrosion inhibitors per- MWF from staining nonferrous alloys tension between incompatible compo-
Hydrocarbon Tail
Polar Head
Additives must perform even more tasks when the lubricant is a MWF.
nents by forming micelles (a submi- water (calcium and magnesium ions) some dyes can pass thru waste treat-
croscopic aggregation of molecules, as on MWF emulsions. Chelating agents ment systems, resulting in pollution
a droplet in a colloidal system). These bind calcium and magnesium salts downstream.
droplets then can remain suspended to prevent them from reacting with Clearly, this is quite a list, and a
in the fluid. Milk is an emulsion. In anionic emulsifiers such as fatty acid chemist’s skill is needed to keep ev-
MWFs, examples of emulsifiers are so- salts of alkanolamines. An example erything under control. Arbitrary use
dium petroleum sulfonate and alkanol- might be ethylenediaminetetracetic of additives at the tankside carries
amine salts of fatty acids. acid (EDTA). substantial risk, if not done under
Detergents and emulsifiers all are Antimist Additives minimize the the supervision of a chemist familiar
similar in that they typically have a so- amount of lubricant that disperses into with the original formulation. Thus,
called polar (hydrophilic) head and a the air during machining. They are typ- it is important to have a good work-
hydrocarbon (hydrophobic) tail. The ically polymers and/or wetting agents. ing relationship with top suppliers of
nature of these two parts depends on For oil-based systems, ethylene, pro- lubricants, MWFs and additives. The
the application. Dispersing and/or pylene copolymers and polyisobutenes pages of TLT are full of ads from such
emulsifying dirt, oils etc., is what you are used. For water-based systems, companies.
do when you wash your hands—you polyethylene oxides are typical. STLE certification holders are
form micelles to solubilize and dis- Finally, Dyes give the lubricant or aware of all these issues. They main-
perse the dirt and oils. MWF a specific color type desired by tain good relations with suppliers, and
Couplers assist in stabilizing water- the customer. After all, “Everybody they can keep your system in balance
dilutable MWFs in the concentrate knows red grease is better than green and safely working at optimum perfor-
to prevent separation of components. grease!” Right! Their main value is in mance levels. Indeed, this is what they
Couplers facilitate formation of emul- water-diluted fluids to indicate that do best.
sions for soluble oils. Examples are product is present, since some of these
propylene glycol, glycol ethers and can be clear and water-like in appear-
nonionic alkoxylates. ance. However, dyes carry some nega- Bob Gresham is STLE’s director
Chelating Agents (also known as tives as well, as they can stain skin and of professional development.
water softeners or conditioners) re- paint. Some water-soluble dyes are You can reach him at
duce the destabilizing effect of hard unstable and can change color. And [email protected].
Editor’s Note:
For a more in-depth
overview about greases,
check out the STLE Webinar:
“Fundamentals of Grease,”
presented by Bob Gresham.
Archive recording available
for purchase at the
STLE store. Details at
www.stle.org.
Consistently
consistent
GREASE
Several tests help us ensure that what we want is
what we get—all the time.
ONE OF THE MAIN GOALS IN MANUFACTURING is to make the
same product the same way to the same specifications—or
consistently consistent. In the case of one of the properties
of grease products, we strive to manufacture grease to a con-
sistently consistent consistency. Sound like I’m playing with
you? Perhaps, I am—just a little.
What is consistency in grease? Consistency is a basic
property describing the softness or hardness of a grease, i.e.,
the degree to which grease resists deformation under the ap-
plication of force. Consistency is the one property that is al-
ways specified on purchase (except in the retail world). The
consistency of grease depends a little bit on the viscosity of
the base oil and some additives, and, to a much greater ex-
Consistency is a basic property describing the softness or hardness of a grease.
Figure 1 | In most applications, grease stays put, however, it can “slump” or flow slowly.
(Courtesy of John Doner, ExxonMobil)
tent, the type and proportion of the in the pictures shown in Figure 1.
thickener. Consistency is usually measured by
Why do we care if the consistency means of The Cone Penetration Test,
of the grease is consistently consis- per ASTM D-217. The results also can
tent? One of grease’s jobs is to stay put. be affected by recent agitation or ap-
Grease is a semi-solid that in most applied shear stress. To take this phe-
plications is supposed to remain where nomenon into consideration, grease Figure 2 | A brass cone is dropped into the
it is applied to provide lubricant when is usually subjected to “working” (a grease and measured for penetration. (Cour-
it is needed. Most equipment designs standardized churning process) prior tesy of John Doner, ExxonMobil)
are based on the grease staying put in to measuring its penetration value.
order to lubricate and also to act as a The Cone Penetration Test is one of The sequence in Figure 3 shows
seal to prevent contamination from the most commonly performed tests varying degrees of penetration or con-
entering into the contact area. In some on grease products. In the test, a brass sistency with the left-hand picture de-
designs, the grease is asked to “slump” cone is dropped into the grease and picting the beginning alignment of the
or flow but slowly. Further, the con- the degree to which the cone pen- cone, the middle picture shows the
sistency might need to be adjusted to etrates into the grease is measured on cone dropped into a thicker grease, and
enable pumping through a central lu- the dial in millimeters. Figure 2 shows the right-hand picture shows the cone
brication system, especially in winter. a picture of the penetrometer, the de- dropped into a slightly less thick grease.
This property, slumping, is illustrated vice used to measure penetration. Grease can be affected by agita-
Figure 3 | Varying degrees of grease penetration.
tion or shear stress. To determine this Table 1 | NLGI Classification System for
property, we drive a perforated plate Rating Grease Consistency.
through the grease via a so-called stro-
ker for a specified number of cycles, Worked NLGI Grease
usually 60 strokes. But for applications Penetration Grade Consistency
where shear stability is critical, 100,000
strokes are applied. This equipment is 445-475 000 Semifluid
shown in Figures 4 and 5.
The National Lubricating Grease 400-430 00
Institute (NLGI) has developed a clas-
sification system for rating the consis- 355-385 0
tency of greases based on the millime-
ters the cone penetrates the grease, as 310-340 1 Figure 4 | Stroker
shown in Table 1.
265-295 2 Smooth
Consistency is the one 220-250 3
property that is always 175-205 4

specified on purchase
(except in the retail world). 130-160 5 Hard/Block
Figure 5 | Perforated Plate
Table 2 | Reproducibility and Reproducibility of ASTM D217.

Grease with a penetration of 265-
295 millimeters is classified as a NLGI Repeatability, Reproducibility,
No. 2. This grade is far and away the Penetration Penetration Range One Operator and Different Operators
most common, certainly the default Apparatus and Apparatus
grade for most equipment designs (and Unworked 85 to 475 8 units 19 units
usually what you buy in retail stores).
Worked 130 to 475 7 units 20 units
It has a nice smooth consistency that
allows the grease to be easily spread Prolonged worked 130 to 475 15 units 27 units
onto surfaces, pretty much stays put Block Under 85 7 units 11 units
and yet is thin enough that it can be
pumped in many systems operating at
moderate ambient temperatures. Does the method provide the same tency of greases, ASTM D217, states
Every time we discuss test methods number every time, or does it vary, and that the method’s worked penetration
and the results that we obtain, we need if so, by how much? In ASTM parlance, variability for greases, like a No. 2, for
to take into consideration the preci- precision is stated in their published more than one lab and operator is 20
sion and accuracy of the test method. standards as the repeatability and the units (see Table 2). Thus, in a given sit-
Accuracy seeks to answer the ques- reproducibility of the method. Repeat- uation, the test results could vary by 40
tion, “Did you get the correct measure- ability has to do with the difference units (+/-20) and statistically have the
ment value?” Bias is a systemic error between two test results performed by same result.
that contributes to the difference be- the same operator in the same labora- So what we find at the end of the
tween the mean of a large number of tory with the same apparatus on the day is that to make a grease of consis-
test results and an accepted reference same test material under constant tently consistent consistency, we must
value. The accepted reference value is operating conditions. Reproducibility use a method that in and of itself is not
considered the true value and there- has to do with the difference between especially consistently consistent. For-
fore, bias has to do with the degree to two single and independent results ob- tunately, for the industry’s needs, the
which that true value is not obtained. tained by different operators working method seems to be neither a blessing
Thus, in general, through calibration, in different laboratories on identical nor a curse; rather, it is good enough.
bias can be reduced or eliminated. test material in the normal and correct But specification writers need to be
Precision has to do with the variability operation of the test method. aware of these kinds of issues when
of the test method itself. The method for measuring consis- they write their specifications.
green
The global case for
Good intentions aren’t enough.

You must get all parts of your operation
working in environmental harmony.
“GREEN” HAS PRETTY WELL TAKEN OVER OUR CONSCIOUS LIVES. Everyone, at least in
the reasonably industrialized nations, is embracing the green culture on some level.
Sure, there are plenty of environmental wackos of whom my father would say,
“I could throw a dog through the cracks of their reasoning.” However, smart in-
dustrial managers think in terms of sustainability and so-called green chemistry.
Remember, sustainability is the idea that we need to make our efforts and pro-
cesses sustainable in the long term. On a theoretical level, the goal is to live off the
sun with maximum efficiency. Ideally, we should survive as long as the sun does.
An easier way to look at sustainability is meeting the needs of the present, with-
out adversely affecting the future, to quote STLE-member Jim D’Arcy of GM. Green
chemistry is the idea that we design chemical products and processes to reduce
or eliminate the use or generation of hazardous substances. Aside from obvious
toxicity in the definition of “hazardous,” we also can include a reasonable level of
biodegradability or at least reduce the hazards to the environment. The concepts
of sustainability and green chemistry must involve global cost-competitiveness.
Global here means not only geographically and geopolitically but also from a total
systems perspective that is consistent with productivity and profitability.
The concepts of sustainability and green chemistry
must also involve global cost-competitiveness.
Properly managing fluids and waste streams is an oppor- cling materials at every stage of the product life cycle
tunity to maximize profitability, internalize the environmen- with the objective of improving the environment at
tal culture and enhance the company’s green image in the each of these stages. This is pretty self-evident, but the
community. With proper attention, waste and fluid manage- key is that every manager and employee must buy into
ment can be a source of indirect revenue by reducing both the concept.
new lubricant purchases and the cost of waste treatment, The second part of this is tracking performance;
selling certain wastes as boiler fuel, reducing negative en- most of these improvements are achieved in small in-
vironmental impact and eliminating fines and a negative so- crements, so-called cherry-picking. Do we have a pro-
cietal image. In other words, a global business case can and active oil analysis program that tells us what we need
should be made for proper fluid and waste management to to know about our fluids in use? Can we extend lube
achieve green goals. change intervals by modest recycling or refurbishing
All this sounds good, but note that the following tenets of the fluid at tank side by filtration, dehydration or
are essential if your program is to work: another simple process? Can we use a fluid that is
more biodegradable or less toxic, which, in turn, puts
1. A proactive maintenance program must be in place and less load on our waste-treatment budget and reduces
operating properly. This is important because fixing health and safety costs related to employee exposure?
leaks comes first. This directly reduces new lubricant The point is, by looking for opportunities at all as-
costs as we decrease waste—plus we protect the envi- pects of the operation, the dividends continually add
ronment by reducing pollution load and minimizing up to substantial cost savings, leading to a more sus-
employee exposure. tainable, greener life as well as improving profitability
Second, by proactively ferreting out root causes of and productivity.
equipment failures and fixing them, we reduce down-
time, the costs of spare parts, overtime, etc. Third, 3. Whether new, used, refurbished or recycled, only use
we save the costs associated with manufacturing and lubricants or metalworking fluids meet the specifica-
shipping new parts, calling people in on overtime to tions for their application. This is very important.
fix broken equipment and so on. All this leads to liv- For example, it is a good idea to reduce inventory
ing more efficiently and, therefore, more sustainably. costs by consolidating lubricants. It makes sense to
recycle or refurbish lubricants to extend their usable
2. A top-down commitment must be made to reducing life. But it makes no sense to risk a multimillion-
waste and pollutants, conserving resources and recy- dollar piece of equipment using fluids that don’t meet
Green chemistry is the

idea that we design
chemical products and
processes to reduce or
eliminate the use or
generation of hazardous
substances.
specification. This again goes to the cherry-picking
idea—where it works, it works; where it doesn’t, it
doesn’t. But at least through a proper risk assessment All too many plant operations people
you can justify the costs in real dollars and cents.
are not particularly aware of the
4. Recycling only makes sense when a global business issues affecting the operation of the
case can be made for it. This, too, is somewhat self-
evident or should be. By tracking the costs at every
waste-treatment plant.
stage of the product life cycle, we have a viable tool
for measuring the impact of any changes on the whole
business. The idea of sustainability is inherently a
global concept. Thus, our thinking regarding mainte-
nance and fluid management has to be global as well.
I hope it is clear that a global approach to manufactur-

ing is needed for success. Compromising product quality,
machine and tool life, manufacturing productivity and the
environment is just not acceptable. Rather, we want to maxi-
mize each of these in concert. Whether directly or indirectly,
these can be measured by global financial results—the over-
all system must reduce total cost per unit manufactured to
achieve maximum profitability.
All that is fine, well and good, but sooner or later you
have to send your spent fluids to the waste-treatment plant.
This, too, should be part of our global business case and part
of our thinking regarding sustainability and use of green
chemistries.
While listening to STLE-member John Burke of Hough-
ton International give a presentation on waste management
as part of STLE’s Metalworking Fluids certificate course, Thus, to the extent that we can use green chemistries in
I was struck by another indirect factor impacting the cost the types of chemicals and the fluids as purchased, or the ad-
of waste management. This has to do with managing the ditives used at the tank side to maintain the fluid life, we re-
chemistries of the fluids and additives used in our processes duce the load on the waste-treatment plant and reduce cost.
to minimize negative impact on the waste-treatment system Clearly, this is a balancing act. The more stable the fluid dur-
operation and costs. ing its use, the longer it lasts and the less frequently we send
One of the more common and cost-effective waste-treat- it to the waste plant.
ment systems is chemical treatment. This involves separating On the other hand, if the fluid is so stable (not green) that
waste oil from water through chemical additions to achieve we can’t treat it without resorting to extreme measures, the
precipitation and flocculation, then settling or flotation of money we saved in the operations is consumed in the waste-
oil-containing wastes. These wastes then are removed by fil- treatment plant, possibly for an overall net loss. Again, this
tration or drawing off the concentrate from either the bottom shows the importance of global thinking in our operations.
or the surface, depending on the nature of the waste. Probably the simplest thing we can do in the plant is use only
All too many plant operations people are not particularly very good quality water. If the quantity of deleterious ions in
aware of the issues affecting the operation of the waste-treat- the water is low, then we won’t need the quantity of additives
ment plant. This is especially the case when multiple waste to overpower them. With fewer additives, whether green or
streams from a wide variety of operations are dumped into not, the treatment plant costs less to operate.
the treatment system. Thus, a well-meaning operations man- Smart managers think in terms of sustainability and so-
ager can inadvertently cause the waste treatment plant man- called green chemistry. Sustainability is the idea that we
ager major problems and add significant cost to the overall need to make our green efforts and processes sustainable in
operation of the plant. the long term. Green chemistry is the idea that we design
In chemical treatment of waste, we are basically reversing chemical products and processes to reduce or eliminate the
everything we have done to make the fluids we are using sta- use or generation of hazardous substances. All these efforts
ble—this is a key concept. In the waste-treatment plant, we only make sense if a global business case can be made. Sav-
add any of a number of additional chemicals to overpower ing money and improving productivity, safety and profitabil-
the chemicals used to stabilize the fluid. ity all are part of sustainability thinking.
Bearings and their lubrication

This primer will help you understand the basics—and
prepare for the CLS exam.
SOME TIME AGO I WROTE ABOUT HOW PEOPLE should work through the pro-
cess of how bearings are used in their plants before blaming the bearing
manufacturer or lubricant supplier for a failure. This is both a simple and
yet difficult subject for the average person responsible for equipment that
has bearings.1
Key points of the article were to first ascertain such things as:
• Was the right bearing installed (size, type, etc.)?

• Was the installation correctly carried out (seated properly, alignment
checked, etc.)?
• Was the bearing correctly lubricated with the right lubricant and did
the lubricant meet proper specifications for the service?
• Were the seals the right type, properly installed and adjusted?
• Was the equipment operated within design limits?
• Was there any chance for contamination during any of the above?
Examples of such bearings include:
Plain bearings are compact, lightweight and Plain Journal Bearings
have a high load-carrying capacity. Design Characteristics
There are also more obscure failure modes such as pitting

due to electrical arcing across the bearing or false brinnelling
when shipping cars or machinery long distances and the ma-
chine bounces or rocks back and forth on the bearings. Per-
haps you can think of other examples, but the point is this: It
is not until these kinds of questions are answered that we can
start to become suspicious of the equipment manufacturer,
bearing manufacturer or lubricant manufacturer.
In the previous article, in the interests of brevity, I did
not cover the basic types of bearings we most commonly Plain Sleeve Bearings
encounter. Unless we are designing the equipment or work
for a bearing company, a basic knowledge should be enough.
When you purchase the equipment, the manufacturer and
bearing company will have figured out the proper type of
bearings. Assuming you use the equipment as intended, ev-
erything should work out. They also should recommend a
maintenance cycle and procedure; again things should work
out if you use the equipment as intended.
BEARING BASICS
So we can all catch up, the purpose of this article is to review
the basic types of bearings, both plain and rolling element. In addition to these designs, there are also plain spherical
A plain bearing, also known as a plane bearing or a fric- bearings and plain angular contact bearings.
tion bearing, is the simplest type of bearing, comprising just
a bearing surface. A simple linear bearing can be a pair of flat Plain Spherical Bearings
surfaces designed to move—for example, a desk drawer and
the slides it rests on. In a shaft application, the journal (the
part of the shaft in contact with the bearing) slides over the
bearing surface either axially or radially, or I suppose both.
Plain bearings are the least expensive type of bearing.
They are also compact, lightweight and have a high load-car-
rying capacity. Lubrication is generally provided by grooving
that supplies and distributes the grease or oil (grooves are
placed out of the load zone). The correct oil film thickness is Best suited for applications requiring loads under oscillatory and/or
determined by viscosity, surface roughness, speed, load and continuous rotational motions. They are also intended for applica-
clearances for the specific application. tions with angular misalignment.
When up to
speed, the lubri- Plain Angular Contact Bearings
cation regime is Figure 1
hydrodynamic.
Thus, theoreti- Best suited for applications
with heavy loads, single di-
cally the bearing
rection, thrust load. If
can last forever, as
thrust load reverses, an an-
shown in Figure gular contact bearing will
1, where the jour- separate. For applications
nal runs on a full requiring reversing thrust
film of oil with no load, use a pair of angular
real wear. contact bearings.
For those applications where the load is purely axial,
there are thrust ball bearings:
Angular ball bearings are
designed to handle both radial Thrust Ball Bearings
and light axial loads.
The next ma- Figure 2 | Deep Groove Ball Bearing

jor class of bear-
ings is rolling el-
ement bearings,
which the ball
bearing is one of
the most com-
mon. Ball bear-
ings tend to have The next major class of rolling element bearings is the
lower load capac- roller bearings. These are designed for higher loads and han-
ity for their size dle similar design problems as ball bearings. First of these
than other kinds is the tapered roller bearing where the key element in the
of rolling element design comes from the fact that cones (see Figure 3) can roll
bearings due to over each other without slipping.
the smaller con-
tact area between the balls and races. They can tolerate some
minor misalignment of the inner and outer races. Figure 3
Of the various ball bearing types, one is the so-called
deep grove ball bearing (see Figure 2).
In a deep-groove radial bearing, the race dimensions
are close to the dimensions of the balls that run in it. Deep
groove bearings can support higher loads because of more
area of surface contact.
Angular ball bearings are designed to handle both radial
and light axial loads.
Similarly, for applications where axial loads are part of the
design as well as radial loads, there are axial ball bearings,
which are a more extreme version of angular ball bearings.
For those applications where the shaft may stress the
bearing by not staying perfectly aligned, there are self-align-
ing ball bearings. Again, when some flex is experienced or angular error in
alignment can be expected, there are spherical roller bear-
ings. For high radial load applications, there are cylindrical
Self-Aligning Ball Bearings roller bearings. And for high-load thrust bearing applica-
tions, there are thrust tapered roller bearings. These bearings
enable axially very compact bearing arrangements. They can
carry very heavy axial loads, are insensitive to shock loads
and are stiff. They are available in single-direction tapered
roller thrust bearings and double-direction tapered roller
thrust bearings.
Likewise for high thrust loads, there are cylindrical
roller thrust bearings. Cylindrical roller thrust bearings are
suitable for heavy axial loads. They are relatively insensi-
tive to shock loads, are very stiff and require little axial
space. Further, they are usually available as single-direction
bearings, which can only accommodate axial loads acting
in one direction.
Needle Bearings
Spherical Roller Thrust Bearings
One of the most versatile designs is the spherical roller

thrust bearing. Here, the load is transmitted from one race-
Jewel Bearings in a watch
way to the other at an angle to the bearing axis. Thus, they
can accommodate radial loads in addition to simultaneously
acting axial loads. Their self-aligning feature makes them can enter the intake air and have a negative impact on ex-
relatively insensitive to shaft deflection and misalignment. haust emissions in the turbocharger. Also, oil supplied to a
They can, therefore, support very heavy axial loads and rela- roller bearing creates some level of hydrodynamic drag. That
tively high-speed operation. is eliminated in an air bearing. Oil will coke if the engine is
A special case of rolling element bearings are needle bear- turned off when the turbo is still very hot.
ings. Needle bearings have a large surface area in contact Further, an oil-lubricated turbocharger would need to
with the bearing outer surfaces compared to ball bearings. be designed to supply oil and with drain hoses and perhaps
They are compact—less added clearance (difference between a cooler, all of which increases cost and complexity of the
the diameter of the shaft and the outer diameter of the bear- turbo. Use of plain and rolling element bearings would need
ing). Thus, they can handle extremely high radial load-car- a relatively large blade tip clearance, whereas air bearings
rying capacity. have a very low profile.
Some specialty types of bearings include magnetic bear- Well, that is probably more than you ever wanted to know
ings, which suspend the shaft by electromagnets surround- about bearing designs. Yet, for those preparing for the CLS
ing the shaft. Thus in operation, it exhibits no wear and, of certification examination, you will need to have an aware-
course, very low friction. Obviously these are very expensive ness of the different kinds of bearings and how to trouble-
bearings to purchase and operate. shoot them.
Jewel bearings are yet another unusual type but which are
commonly used in clocks, watches and other fine mechanisms.
They can be extremely small and often are not lubricated. REFERENCES
Finally, air bearings are yet another specialty bearing, 1. Gresham, R.M. (2005), “When Bad Things Happen to
which overcomes the disadvantages of oil or grease lubrica- Good Bearings,” TLT, 61 (12), pp. 18-19.
tion systems in equipment such as turbochargers. Here oil
The basics of filters and filtration

Establishing a good relationship with
your supplier is the best strategy to using
these materials successfully.
FILTERS AND FILTRATION ARE SUBJECTS that seem simple to understand on

the surface but, like so many things, are much more complex in detail.
And, of course, the devil is in the details. It is well beyond the scope of this
article to delve too deeply, as there just isn’t enough space in this issue.
For example, there are a wide variety of filters used in the chemical
industry to separate a crystalline product from its reaction mass; we are all
familiar with various air filters, starting with those used in our home heat-
ing systems or automobiles, and there are a large number of liquid fluid
filters ranging from beer to gasoline.
When you boil it down, solids, liquids or gases can contaminate solids,
liquids or gases—that covers a lot of ground. Nevertheless, the basic prin-
ciples by which all these different filter problems are managed are funda-
mentally the same, but the details are often unique. So let’s try to limit the
playing field and just look at the very basics.
First, let’s only look at the removal of relatively large (> 1-5 micron)
insoluble contaminants via a porous medium, as typically encountered in
the lubricants industry. These are also the more common kinds of filtra-
tion problems. There are three major types of filters: line to insure that we don’t add contaminants to the reser-
voir. What’s the pressure and flow of the fill pump? After the
1. Mechanical. Metal screens or discs that remove only reservoir is filled, we will need a breather cap fitted with a
coarse particles. filter to keep dust and airborne contaminants from entering
2. Absorbent (inactive). Resin-impregnated paper, cotton, the reservoir as tank levels fluctuate. Then we should have a
etc., that remove smaller particles and some water. filter (often just a screen filter) on the intake line at the bot-
3. Adsorbent (active). Charcoal, diatomaceous earth, tom of the reservoir (where a lot of big stuff tends to settle)
which is not used in hydraulics because it may strip and another finer lower-pressure filter just before the pump
additives. to protect it. Then another higher pressure filter on the out-
put side of the pump (the pump tends to grind dirt and gen-
There is also gravity/density filtration (centrifuge and set- erate wear particles, as well).
tling), vacuum dehydration (removes water only) and ultra- At this point, the actuators and control valves should be see-
filtration (removes oil and certain larger particles). These are ing pretty clean fluid. However, as the fluid returns from the
well beyond the scope of this article. actuators, the fluid picks up contaminants from rod seal leak-
For this discussion, we are considering absorbent (inac- age, so we need a filter on the return line to the reservoir. Then,
tive) filters. Probably the most important recommendation if that is not enough, in some systems it is also necessary to
from this article would be to develop a good relationship employ an offline filter connected to the reservoir (see Figure 1).
with your filter supplier, as he can guide you in making the
right choice of filters and how best to use them. I hope the
wisdom of this will become apparent. There are some terms
often used: nominal rating (rates size of pores in filter, for
example, 5-micron nominal), absolute (gives largest opening
in media) and beta ratio/efficiency (how many times through
the filter before all particles of a certain size are removed).
Regarding beta ratio, the idea is to rate the efficiency of
the filter. For example, if we pass a fluid (notice I said fluid,
because the fluid could be air or hydraulic fluid) with 1,000
particles > 5 microns through a nominal 5-micron filter and
we measure 500 particles > 5 microns in the output, then the
beta ratio is 1,000/500 = 2, which represents an efficiency of
50 percent. Or if we pass a fluid with 1,000 particles > 5 mi-
crons through a 5 nominal micron filter and 10 particles > 5
microns pass through the filter, then the rating is 100. This Figure 1 | Typical filter placement in a hydraulic system.
is written as:
How is a poor soul supposed to sort all this out? Well,
`5 = 1000/10 = 100 there are a number of ANCI and ISO tests that assure filter-
(Note: this represents an efficiency of 99 percent) element quality (burst resistance, element material compati-
bility, flow fatigue resistance, flow versus pressure drop,
Already we are beginning to see that all filters are not the etc.). This is why I think it makes a lot of sense to develop a
same. good working relationship with a credible filter supplier.
In TLT we’ve discussed contamination and the need to set Don’t skimp on the quality or number of filters—get what is
contamination limits for each piece of equipment.1 With this needed for the system. The cost of filters is cheap next to the
information, in a system of several operating components cost of replacing or shutting down a valuable piece of equip-
such as a hydraulic system, we can select the most sensitive ment and interrupting production. Once installed, maintain
machine (component) in the system. In addition, we can be- the filters properly. If you don’t keep the filters working prop-
gin to determine the correct filter placement and establish- erly, it is as foolish as trying to pull up a stump with a logging
ment of a cleanliness target. Further, we need to know the chain tied to the stump with a piece of yarn.
maximum system pressure, the maximum flow through the It is just like the man from the old Fram automobile oil
filter and the viscosity of the fluid. Also, we need to know filter commercials said, “You can pay me now or you can pay
the temperature range and the pressure range that the system me later!”
and filter will experience. Starting to get just a little compli-
cated, isn’t it? REFERENCES
Let’s think about a hydraulic system: first to fill the reser- 1. Gresham, R.M. (2007), “What’s The Deal with Contami-
voir (which we will assume is clean but in practice don’t nation Control,” TLT, 63 (12), pp. 22-24.
make that assumption), we should have a filter on the fill
The mysterious
world of
seals
These important structures play
a major role in making sure
a lubricant stays in place.
(Photo courtesy of SKF USA, Inc.)
IN THE WORLD OF TRIBOLOGY, seals are a bit mysterious. Most The main function of seals can be summarized as follows:
things that move relative to something else need to be lubri- seals are present to prevent or minimize passage of fluid
cated in some fashion—we all pretty much have that figured through gaps between mechanical elements of a machine.
out. And, intuitively, it seems to make sense that to lubricate There are many different types of seals that are used in vari-
two surfaces, we need a way to keep the lubricant where we ous applications.
want it. First, seals can be classified into two major categories: stat-
However, many systems do not have that requirement, ic and dynamic. Static seals, which are the simplest form, seal
including chainsaw bars, trackside lubricators and the rap- two objects together that have relatively little or no motion
idly becoming obsolete two-cycle engines. These all use the such as thermal expansion. These seals are usually in the form
lubricant once and then pass it on irretrievably to the envi- of gaskets or sealant compounds. The more dynamic applica-
ronment. In other more common systems, something must tions (pun intended) require dynamic seals. Of these seals,
help hold the lubricant in place, and that something is a seal. there are two major types: those sealing rotating motion and
But here’s where it gets interesting, the lubricant may not those sealing reciprocating motion (see chart on page 24).
necessarily be a lubricant as we most commonly think of it— As you can see, there are a lot of different kinds of mo-
but I’m getting ahead of myself. tions that must be sealed and a lot of different methods have
been devised to do so. Often these varied designs were the
result of the nature of the material being sealed and the nega-
tive consequences of that material being released into the
environment, especially with regard to employee safety. It is
beyond the scope of this article to go into all the different
designs and materials of construction, except to say that in
addition to sealing some materials in, we may also be sealing
an environment out—or vice versa.
To be less abstract, first consider that many seal designs
need a small amount of lubricant to function. The lubricant
may not be a lubricant as we normally think of it but, rather,
as in a chemical plant, the very chemical we are working
with. Such is the case in sealing a pump shaft for a pump that
is designed for pumping water, solvents, gases, caustic acids,
Industrial Sealing
Static Dynamic
Gaskets Sealants Rotating Shaft Reciprocating Shaft
Interfacial Interstitial (non-rubbing) Piston Rings Packings Diaphram
Axial Radial Labrynth, Bushing,etc.
Mechanical Lip Ring Split Ring Packings
crude oil or whatever. This obviously makes the job more

difficult, as some of these substances are not only potentially
hazardous but also not very good lubricants and may be del- Seals are present to prevent or minimize
eterious to many types of sealing materials. passage of fluid through gaps between
Thus, there are a number of considerations when it comes
to the proper use of seals in machinery. In this article, we’ll mechanical elements of a machine.
review the major issues. Not all seal designs require physical
contact with a mating surface to seal. A good example is lab-
yrinth seals, which provide a tortuous path progressively mon is mishandling, which results in scratches, dings or
building sufficient back pressure to prevent leakage. chips in the seal face. This damage to the seal or its mating
However, with the more common seals that do have con- surface usually occurs during installation, storage or han-
tact, the sliding surfaces of the seals are always lubricated by dling. Misalignment during installation is another major
the fluid sealed or by supplementary lubrication fed directly source of failure.
into the space ahead of an exclusionary seal or from impreg- Even with proper design and installation, we are not out
nated solid lubricants at the seal interface. Therefore, one has of the woods yet. We can have failure at startup where the
to consider wear of both the seal and its mating surface. seal faces are not lubricated. An example would be running
Ideally, the mating surface should be of a hard, wear-resis- the seal dry because a valve on the suction side of a pump
tant material relative to the seal and the substance being was left closed.
sealed (which also can include slurries or other entrained Finally, like most mechanical systems, proper mainte-
particulate material). The hardness of the seal material and nance is important. Two key factors are “unscheduled move-
its compatibility with the fluid sealed are clearly critical fac- ment,” which can be excessive axial or radial movement of a
tors. Thus, ideally, when it is necessary to replace the seal, shaft against the seal; that is, excessive vibration or any other
only the seal should be replaced and the mating surface only kind of related movement that is not part of the design. This
cleaned or lightly polished. could arise from a pump and motor that are firmly attached
High surface-sliding speed and/or excessive pressure be- and aligned to a solid base. The other key factor is excessive
tween sliding surfaces increases temperature. At low speed contamination, which is often due to improper maintenance
with high pressure, lubrication may be difficult. These fac- of filtration systems.
tors can change seal/face geometry, which results in seal fail- Like so many things we encounter in this tribologically
ure. As alluded to above, abrasives in the fluid sealed or influenced world of ours, there is often more to it than meets
rough seal seats or mating surfaces can cause damage and the eye, and seals are no exception. Without effective seals,
leakage. Abrasion resistance of the seal material is an impor- our cars burn oil (bad rings), our environment is polluted
tant factor. Interestingly, too much or too little surface due to leakage, employee safety can be jeopardized and the
roughness on sealed surfaces can equally be a problem. workplace becomes a pig sty with material leaking across the
floor and a haze in the air.
SEAL FAILURE In 1993 the Clean Air Act was introduced and since then
Given the proper design considerations of speed, pressure, the seal industry has implemented many very effective prac-
abrasion resistance, chemical resistance, surface roughness tices when it comes to the proper installation and mainte-
and materials of construction, there are other important fac- nance of seals. Even the most cursory look at our environ-
tors that can result in seal failure. Probably the most com- ment versus 20 years ago clearly shows these advances.
TURBINES:
What goes around comes around
There are three main types of turbomachinery,
and each has its own set of lubrication requirements.
I MAKE NO CLAIM TO BEING AN EXPERT IN TURBOMACHINERY, but these

gadgets have always intrigued me as a class of machinery. At STLE’s
Annual Meeting & Exhibition, most of the education courses and
practical papers tend to gloss over lubrication of turbomachinery.
So here goes.
In the world of turbines, there are three main types: hydro, steam
and gas. Well, I guess you should also include wind turbines, but they
are quite a bit different than the above three. While I suppose you
could call wind turbines a special case of a gas (air) turbine, to me
they are a big wind-driven propeller hooked up to a gearbox that is, in
turn, hooked up to a generator or alternator.
The main lubrication issues for hydro-turbines are
water contamination and service life.
HYDRO-TURBINES bility are needed. The long service life is desirable to reduce
These machines are driven by water and connected to an maintenance costs and downtime. These are important due
electricity generator or, more properly, a turbo-alternator to the physical location of these turbines and the need for
to produce electricity. Hydro-turbines are on the low end in uninterrupted electrical power output.
terms of application requirements but still significant. Thus,
the lubricating oil sees temperatures in the oil sump on the STEAM TURBINES
order of 40 C-60 C with peak temperatures in the circula- Industrial steam turbines have multiple uses, usually to drive
tion system to maybe 70 C-95 C. Speeds are also moderate at compressors, turbo-alternators, blowers, pumps and the like.
around 50-600 rpm. In compressor applications, steam turbines and the compres-
The oil also must lubricate guide vanes and control sys- sor itself are similar in that they are both turbomachines. As
tem components. The main lubrication issues for these kinds such, they can behave similarly in terms of speed versus out-
of turbines are water contamination and service life. Thus, put. Thus, steam turbines are excellent for variable-speed
mineral oil-based R&O oils that have good water demulsi- turbo-compressors.
Figure 1 | Schematic of a hydro-turbine installation.
Figure 3 | Schematic of a hydro-turbine.
Figure 2 | Schematic of a steam turbine. Figure 4 | A steam turbine installation.
Figure 5 | General Electric LM2500 Gas Turbine
Steam turbines can take on many different configura- solublize varnish rather than letting it form deposits.
tions, an analysis of which goes beyond the scope of this More modern formulations along with effective filtration
article. However, all multistage steam turbines require cool, generally manage excessive varnish formation, or at least
clean oil supplied to their journal bearings. they should. Such oils typically have a viscosity index (VI)
This oil is supplied from several types of systems, but the in the range of 95-100 so that the viscosity doesn’t vary too
key is that the oil must be delivered at the right flow rate, much from startup to peak temperatures.
pressure and temperature. Often the driven equipment, such
as the compressor, is also lubricated with the same oil, again GAS TURBINES
at the right level of cleanliness, flow, pressure and tempera- Industrial gas turbines, which are basically land-based jet en-
ture. Furthermore, additional equipment also might be lu- gines (windmills notwithstanding), have some similarities to
bricated by this same system such as various control valves. steam turbines except that steam is replaced with hot com-
bustion gases. Thus, water contamination is not so much
a problem with gas turbines. However, sump temperatures
can range between 50 C-100 C with hot spot peaks up to
In compressor applications, steam turbines 280 C. Speeds also are higher on the order of 3-7,000 rpm.
Therefore, the performance requirements of the lubricating
and the compressor itself are similar in that oil are necessarily higher, while lubricating oils based on
hydro-treated basestocks are used for the less stringent ap-
they are both turbomachines. plications.
Clearly, gas turbines are a good application for synthetic
lubricants such as polyalphaolefins and ester-based oils.
In general terms, steam turbines can operate up to speeds Many of the larger, higher-performing industrial gas turbines
of 3,000 rpm, oil sumps around 40 C-70 C with peak or hot (like the one shown in Figure 5) often use an aircraft engine
spot temperatures as high as 150 C. Clearly, aside from par- core and require similar lubricants. For more advanced air-
ticulate contamination, which is always a problem, steam craft jet engines, which really are just higher-performing gas
turbines are subject to the effects of water and steam. Typi- turbines, we have to kick it up a notch.
cally turbine oils for steam turbines must be primarily re- These turbines use primarily ester-based lubricants for
sistant to rust and oxidation, the so-called R&O oils. Addi- their wide-temperature range capabilities such as those
tionally, turbine oils may contain antiwear and EP additives. described by military specifications MIL-L-7808 and MIL-
Further, they should exhibit good demulsibility of water and L-23699. For even higher-temperature resistance with oper-
be low foaming. ating temperatures as high as 300 C, polyphenylether lubri-
Interestingly, when one thinks about the highly formulat- cants, as described in MIL-L-87100, could be used. But these
ed automotive oils (10-20 percent additives), turbine oils by are not for the financially faint of heart, and the polyphenyl-
contrast are typically formulated with not much more than ethers have poor low-temperature performance, which is not
1 percent additives. Therefore, the base oils are important. so critical for an industrial gas turbine but can be a show-
They can vary from Groups II, III, III+ or IV. The higher re- stopper for an airplane.
fined oils tend to have more inherent oxidation stability but, Clearly, turbomachinery, like the applications described
especially in the old days, they also tended to exhibit more above, affect our everyday lives in many ways. Keeping them
varnish formation, likely because less refined oils tend to going around allows us to go around.
What’s a
gear?
An overview of the
machine elements
that keep the
industrial world
turning.
Gears are classified according to the relative position of the axis of their revolution.
HOW MANY OF YOU ARE OLD ENOUGH TO REMEMBER WALT DIS-

NEY’S GYRO GEARLOOSE? Probably not many. I suppose he was
the first fictional tribologist. In fact,
old Gyro was around before the word
tribologist was coined. Gyro, who first
appeared in Walt Disney Comic Book
No. 140 in 1952, was a brilliant inven-
tor of all kinds of humorous gadgets
and devices, many of which included
quite novel gear sets.
One can’t help but wonder how much he knew about the
lubrication of his somewhat uniquely geared inventions. So
let’s take a brief look at the world of gears.
First a definition: Gears are machine elements that trans-
mit motion by means of successively engaging teeth. The
gear teeth act as small levers. In general, gears are classified External Spur Gears
according to the relative position of the axis of their revo-
lution. Thus, these axes are parallel, intersecting or, as you
might guess, neither intersecting nor parallel—but non-in-
tersecting.
Thus, gears connect shafts that operate from these differ-
ent directions and, depending on the relative diameters and/
or numbers of teeth per gear, can multiply speed or force in a
manner analogous to a lever. So gears can reduce or increase
speed, transmit power, increase or decrease torque, change
direction and change axis of direction. Pretty handy traits for
design engineers. Some of the more common gear types are:
SPUR GEARS
Spur gears or straight-cut gears are the simplest type of gear.
Spur gears connect parallel shafts and have involute (curling
inward) teeth, parallel to the shafts (see diagram).
Internal Spur Gear
Spur gears consist of a cylinder or disk with the teeth

projecting radially and, although not straight-sided in form,
the edge of each tooth is straight and aligned parallel to the
axis of rotation. These gears can be meshed together cor-
rectly only if they are fitted to parallel shafts. Spur gears are
relatively inexpensive to manufacture, cause no axial thrust
between the gears and, while giving lower performance than
other gear types, are generally satisfactory in low-speed, sim-
Involute Tooth ple applications. They can be noisy at higher speeds.
INTERSECTING SHAFT GEARS
Bevel Gears Zerol Gears Spiral Bevel Gears Hypoid Gears
HELICAL GEARS BEVEL GEARS

Helical gears offer a refinement over spur gears. Helical Bevel gears have a conical configuration as opposed to cy-
gears can be meshed in parallel or crossed orientations. He- lindrical for spur and helical. Thus, the two gears are, in
lical gears also have involute teeth and are cut at an angle effect, two truncated cones in rolling contact. Within this
(called the helix angle) to the axis of rotation. Since the gear configuration there are straight bevels, which are like spur
is curved, this angling causes the tooth shape to be a segment gears with no helix angle. Examples of bevel gears are mi-
of a helix. The mating gears must have the same angle but ter gears, equal in size with a 90-degree shaft angle, angu-
in opposite hands (left and right). The angled teeth engage lar gears with shaft angles other than 90 degrees, and crown
more gradually than do spur gear teeth, causing them to run gears where one gear is flat with a pitch angle of 90 degrees.
more smoothly and quietly because there is continuous tooth Zerol bevel gears are an intermediate type between straight
contact. A disadvantage of helical gears is a resultant thrust and spiral bevel gears. Their teeth are curved or crowned, so
along the axis of the gear, which needs to be accommodated that contact takes place at the tooth center but not angled.
by appropriate thrust bearings. The greater degree of sliding Spiral bevel gears are analogous to helical gears but with a
friction between the meshing teeth is often addressed with conical configuration. A hypoid gear is an example of a bevel
antiscuff and antiwear additives in the lubricant. gear that is neither parallel nor intersecting. Other examples
Helical gears are found in high-speed applications where of non-parallel and non-intersecting shaft gears are crossed
good performance is needed. As you might expect, they can helical gears and worm gears.
carry higher loads as there is a greater tooth cross section. Ob- Crossed helical gears are used where the shafts are not
viously, they are more expensive to manufacture. Another way parallel and not intersecting but rather skewed. They can
to combat the axial thrust property is to use herringbone gears. be at 90 degrees or other angles. The teeth necessarily slide
more and are, therefore, less efficient and often require high-
HERRINGBONE GEARS ly additized lubricants.
Herringbone gears consist of two helical gears of opposite Worm gears are used when large gear reductions are
hands that are mounted side-by-side on the shaft and thus needed. It is common for worm gears to have reductions of
cancel the resulting thrust forces. 20:1 and even up to 300:1 or greater. Many worm gears have
Parallel Helical Gears Crossed Helical Gears Herringbone Gears
Figure 1 | Key Elements of Gear Design Rack and pinion (The rack is like a gear
whose axis is infinity)
an interesting property that no other gear set has: the worm

can easily turn the gear, but the gear cannot turn the worm.
This is because the angle on the worm is so shallow that
when the gear tries to spin it, the friction between the gear
and the worm holds the worm in place. This feature is useful
for machines such as conveyor systems in which the locking
feature can act as a brake for the conveyor when the motor
is not turning.
ROTARY TO TRANSLATION GEARS

Crossed Helical Gears
These gears transmit rotary motion from the pinion to trans-
lational motion of the rack. The rack amounts to a gear of
infinite radius with flat involute teeth.
The different designs of gears is an extremely complex
subject and beyond the scope of this article. Figure 1 depicts
a diagram of a gear that shows the key elements of gear de-
sign.
Gears are made from a variety of materials dependent
upon cost and the application. These materials include cast
iron, powdered metals, steel, a variety of special nonferrous
alloys and non-metallics such as the group of engineering
plastics: nylon, acetal, UHMWPE, etc.
Gears are used in a wide variety of combinations in a wide
Worm Gears variety of applications, such as in clocks, copiers, huge bull
gears in drag lines, drawbridges, industrial gearboxes and re-
lated industrial equipment and, of course, truck and automo-
bile transmissions and differentials.
Basic Handbook of Lubrication
Third Edition
The only reference you need to
understand tribology fundamentals!
Edited by STLE’s Alberta Section, the Basic Handbook of
Lubrication (Third Edition) is a comprehensive text authored
by more than 25 contributors. At 360 pages, this technical
reference thoroughly covers some 30 topics with material
edited to help newcomers and veterans to the lubricants
industry. This reference is included in the recommended
study material for STLE’s Certified Lubrication Specialist©
and Oil Monitoring Analyst© (I&II) certifications.
CHAPTER TITLES
• Oil viscosity & selecting correct grade • Turbine oils

depending on temperature • Refrigeration system lubrication
• Friction and lubrication regimes • Grease, an introduction
• Mineral base oils • Solid film lubricants
• Synthetic base oils and finished lubricants • Metalworking & preservative fluids
• Used oil re-refining to create base oils • Environmentally friendly lubricants
• Additives used in formulating lubricants • Solvents & cleaners
• New lubricants – analysis & testing • Aftermarket additives
• Bearing lubrication • Centralized lubrication systems
• Engine oils • Pneumatics
• (Stationary) natural gas engine lubrication • Filtration
• Enclosed gear oils: Classifications and • Introduction to seals
additives • Wear types
• Hydraulics fluids & related properties • Degradation and analysis of oils
• Hydraulic system components in service
• Hydraulic system components – sample • Condition monitoring & industrial
calculation machinery
• Hydraulic system components – sample • Effective bearing failure analysis
calculation appendix • A guide to purchasing lubricants
• Air compressor lubrication • Storage of new lubricants (health, safety
• Reciprocating natural gas compressor and environmental considerations)
lubrication • Used oil collection
• Lubrication of electric motor bearings • Glossary of lubrication terms
Price: $125 to STLE members. $159 to others.

Comes in spiral-bound and perfect-bound editions.
Available only through STLE! Order at www.stle.org, or call 847-825-5536.

840 Busse Highway, Park Ridge, Illinois 60068
P: 847-825-5536 F: 847-825-1456 www.stle.org [email protected]
Education Your Way. Focused. Flexible. Accessible.
STLE University is your personalized, centralized location for continuing

education in the field of tribology and lubrication engineering. We provide
you with the latest educational information in the field while at the same
time providing opportunities to enhance your career and create value for
your company.
Choose from a variety
STLE University was designed with our members in mind. STLE of educational formats:
provides education that is:
• Focused: STLE offers a variety of courses and webinars that are

Online Offerings
designed for specific audiences working in the field of tribology and
lubrication engineering. Our offerings vary by topical area, level of
• Online certificate courses
expertise (basic to advanced) and audience segment (formulators,
salespeople, distributors, students, etc.). - Fundamentals of Lubrication
• Flexible: Courses are available in-person and online to fit around any • Online short courses
busy schedule, and are designed to meet your varying educational - Basic Lubrication
needs. If you need a short course, an introduction/overview or a
- Lubrication Composition
long, in-depth course, chances are STLE University has something
to fit your needs. There are varying types and formats of courses - Fluid Management & Recycling
to match up with your available time commitment. - Metalworking Fluids
• Accessible: STLE offers a variety of educational opportunities, both

in-person and online. Our in-person education locations change • Monthly Webinars
yearly, ensuring you have a chance to visit one nearby. Our online Topics include bearings, gears,
options allow you to purchase a course at any time and start it hydraulics, MWFs and much
immediately. As long as you have a computer and an Internet con- more!
nection, you have online education. Also, STLE University is not
limited to members. However, you receive significant discounts if you
become a member. In-Person Offerings
All of our educational opportunities also apply towards STLE’s recertifica- • Annual Meeting courses
tion requirements. Visit www.stle.org/university for more information and
schedule of upcoming courses and webinars. • Local Section courses
• Certificate courses
• On-site education courses
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TLT

When it comes to advancing

• 400 Technical Presentations

Visit www.stle.org for regular

Society of Tribologists and Lubrication Engineers

6 The basics of viscosity index

8 The mysterious world of lubricant additives

12 Consistently consistent grease

15 The global case for green

18 Bearings and their lubrication

26 Turbines: What goes around comes around

I HAVEN’T WRITTEN ABOUT VISCOSITY in needed to rotate the spindle). Then we

paint? More effort is required, but for

this quirky viscosity behavior, with the valuable les-

Tangential Stress (F/A)

will eventually thin and not support

The basics of viscosity index

Figure 1 | A lubricant’s variation in viscosity with respect to temperature.

This cuts two ways. When a lubricant is too cold (not up

These are the macro issues. How-

Figure 3 | Varying degrees of grease penetration.

Consistency is the one 220-250 3

property that is always 175-205 4

Table 2 | Reproducibility and Reproducibility of ASTM D217.

Good intentions aren’t enough.

Green chemistry is the

I hope it is clear that a global approach to manufactur-

Bearings and their lubrication

• Was the right bearing installed (size, type, etc.)?

There are also more obscure failure modes such as pitting

The next ma- Figure 2 | Deep Groove Ball Bearing

Spherical Roller Thrust Bearings

One of the most versatile designs is the spherical roller

The basics of ﬁlters and ﬁltration

FILTERS AND FILTRATION ARE SUBJECTS that seem simple to understand on

Gaskets Sealants Rotating Shaft Reciprocating Shaft

Interfacial Interstitial (non-rubbing) Piston Rings Packings Diaphram

Axial Radial Labrynth, Bushing,etc.

Mechanical Lip Ring Split Ring Packings

crude oil or whatever. This obviously makes the job more

I MAKE NO CLAIM TO BEING AN EXPERT IN TURBOMACHINERY, but these

Figure 1 | Schematic of a hydro-turbine installation.

Figure 3 | Schematic of a hydro-turbine.

Figure 2 | Schematic of a steam turbine. Figure 4 | A steam turbine installation.

HOW MANY OF YOU ARE OLD ENOUGH TO REMEMBER WALT DIS-

Internal Spur Gear

Spur gears consist of a cylinder or disk with the teeth

Bevel Gears Zerol Gears Spiral Bevel Gears Hypoid Gears

HELICAL GEARS BEVEL GEARS

Parallel Helical Gears Crossed Helical Gears Herringbone Gears

an interesting property that no other gear set has: the worm

ROTARY TO TRANSLATION GEARS

• Oil viscosity & selecting correct grade • Turbine oils

Price: $125 to STLE members. $159 to others.

Society of Tribologists and Lubrication Engineers

STLE University is your personalized, centralized location for continuing

• Focused: STLE offers a variety of courses and webinars that are

• Accessible: STLE offers a variety of educational opportunities, both

Find out more about STLE! Sign up and follow us on: