4a Lubrication Fundamentals-Mechanisms 2023 E-Learning

4a_ Lubrication Fundamentals, Types & Mechanisms
Lubrication Fundamentals,
Types & Mechanisms
Fundamentals
Prepared by: Prof. Nabil El-Tayeb 1

Nature of friction forces between

two surfaces:
Low and steady which leads to
smooth and easy running,
Great and uneven which makes
movement difficult and
impossible resulting in
overheated and damaged
surfaces






Why do we need
pressure in the
lubricant?
To inhibit
contact between
asperities and to
support external
load

(1)

(2)

(3)


N/m2 = Ps  N-s/m2 = Pa.s





(1)

(2)

(1)

(2)
(1)
(h0.25m)
1. Lubricant film is sufficiently thick, to prevent opposing

surfaces from coming in contact,
2. Lubricant film is many times thicker than surface

roughness
(3)
(2)
3. HD Pressure is low compared to the strength of

material, i.e. solid surfaces are rigid bodies and no
deformation (ideal form of lubrication)
4. Behaviour of contact is governed by the physical

properties of lubricant

(4)
(3)
5. Frictional characteristics are purely from shearing of

viscous lubricant,
6. Geometric profile of lubricant resembles a converging

wedge of journal bearing.

(1)
EHL is: (h0.025-5 m)

1) A special type of HD Lubrication,
2) Occurs in heavily loaded contact, i.e., rolling bearings
and gears,
3) Elastic deformation of bearing surfaces is significant,
(2)
3) Loaded zone is subjected to very high pressure, and the

effect of this high pressure is:
• Increases viscosity leading to higher load carrying
capacity
• Increases loaded zone area due to elastic
deformation leading to higher load carrying capacity

(1)
• Oscillating motion in normal direction (also called

squeeze) can generate pressure in the fluid film,

(1)

(1)
What are the main requirements in the lubricant?
The main requirements from lubricant are:
• Pressure (P) to support the external applied load and
•Viscosity () to separate the loaded contact to minimise the
friction and wear

(2)

(3)



Fig.4.18







(1)
a). Stribeck curve
describes the change in
frictional behaviour of
different lubrication regions
b). Various lubrication

modes (except hydrostatic
and solid lubrication) can
be explained on the basis of
Stribeck curve.
c). Lubrication
parameter (h/) is the
mean film thickness /
composite standard deviation
of both surfaces height.

(2)

(3)

(1)

(2)

(3)

(4)


Metal working fluids (1)

Functions:
1. Reducing friction  force  energy consumption  rise
in temp,
2. Reducing wear (seizure and galling),
3. Reducing thermal distortion of work piece,
4. Flush away the chips from cutting zone (in machning)
5. Improving tool life and surface finish,
6. Improve material flow in tools, dies, and molds,
7. Act as a thermal barrier between work piece and its tool
(die) surface,
8. Helps in the removal or ejection of parts from dies and
molds.
9. Protect the machined surface from environmental
corrosion.

Types:
1. Oils [mineral (petroleum or hydrocarbon), animal, or
vegetable],
• Although they are effective in reducing friction and wear, they
have low thermal conductivity and low specific heat, i.e. they do
not conduct away the heat generated by friction and plastic
deformation,
• Difficult and costly to remove oils from work piece surfaces that
are to be painted or welded.
2. Emulsions {water-soluable oil or water-based coolants}
• A mixture of oil and water with different proportion + additives,
• Indirect emulsion [water droplets are dispersed in oil,
• Direct emulsion [mineral oil is dispersed in water] high cooling
capacity in high-speed machining, because of water

Types:
3. Synthetics and semi-Synthetics Solutions,
• Synthetic solutions contains inorganic and other chemicals
dissolved in water (do not contain any mineral oils),
• Semi-synthetic solutions are basically synthetic solution + small
amounts of emulsifiable oils,
4. Soaps, Greases, and Waxes
• Soaps are reaction product of sodium or potassium salts with
fatty acids. Alkali soaps are soluable in water. Effective solid
lubricant because it can form thick film layers
• Greases are solid or semi-solid lubricants (soap + mineral oil +
additives). They are highly viscous and adhere well to surfaces,
• Waxes [animal or plant (paraffin) origin], compared with
greases, they are less greasy and more brittle.

Additives: (used to change viscosity,
temperature behaviour, surface tension, heat
resistance, and boundary layer characteristics)
1. Oxidation inhibitors,
2. Rust preventing agents,
3. Foam inhibitors.
4. Wetting agents,
5. Odor-controlling agents.


Several considerations of Selecting
Metalworking fluids:
1. Manufacturing process,
2. Processing parameters,
3. Surface preparation required,
4. Materials of workpiece, tool, and die,
5. Compatibility of fluid with the materials of workpiece, tool, and die,
6. Method of applying fluid,
7. Removal of the fluid and cleaning of the workpiece after processing,
8. Contamination of the fluid by other lubricants in the machine,
9. Storage and maintenance of fluids,
10. Treatment of waste lubricant,
11. Biological and environmental considerations,
12. Costs involved


 Viscosity, temperature, and pressure characteristics are important factors
when selecting an oil as a lubricant
 Low viscosity can have significant detrimental effects and cause high friction
and wear,
 “Whether it is primarily a lubricant or a coolant” it is very important factor to
be considered when selecting metalworking fluid.
 Water-based fluids are very effective coolants, but as lubricants, they are not
as effective as oils.
Specific requirements for metalworking fluids:

 It should not leave any harmful residues that could be interfere with
operation,
 It should not stain or corrode the workpiece or the equipment,
 It should be checked (proper inspection and filtering are essential)
periodically to detect deterioration caused by bacterial growth, accumulation
of oxides, chips, wear debris and general degradation and breakdown due to
temperature and time

 Viscosity, temperature, and pressure characteristics are important factors
when selecting an oil as a lubricant
 Low viscosity can have significant detrimental effects and cause high friction
and wear,
 “Whether it is primarily a lubricant or a coolant” it is very important factor to
be considered when selecting metalworking fluid.
 Water-based fluids are very effective coolants, but as lubricants, they are not
as effective as oils.
Specific requirements for metalworking fluids:

 It should not leave any harmful residues that could be interfere with
operation,
 It should not stain or corrode the workpiece or the equipment,
 It should be checked (proper inspection and filtering are essential)
periodically to detect deterioration caused by bacterial growth, accumulation
of oxides, chips, wear debris and general degradation and breakdown due to
temperature and time
Summary
 A wide variety of metal working fluids, including oils,

emulsion, synthetic solutions, and solid lubricants, is available
for specific applications.
 The selection and use of lubricants requires a carful
consideration of many factors regarding the workpiece and die
materials and the particular manufacturing process
 Metalworking fluids have various lubricating and cooling
characteristics. Biological and environmental considerations are
also important factors in selecting a metalworking fluid.

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4a_ Lubrication Fundamentals, Types & Mechanisms

Prepared by: Prof. Nabil El-Tayeb 1

Nature of friction forces between

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N/m2 = Ps  N-s/m2 = Pa.s

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1. Lubricant film is sufficiently thick, to prevent opposing

2. Lubricant film is many times thicker than surface

3. HD Pressure is low compared to the strength of

4. Behaviour of contact is governed by the physical

Prepared by: Prof. Nabil El-Tayeb 23

5. Frictional characteristics are purely from shearing of

6. Geometric profile of lubricant resembles a converging

Prepared by: Prof. Nabil El-Tayeb 24

EHL is: (h0.025-5 m)

3) Loaded zone is subjected to very high pressure, and the

Prepared by: Prof. Nabil El-Tayeb 27

• Oscillating motion in normal direction (also called

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b). Various lubrication

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Metal working fluids (1)

Metal working fluids (2)

Metal working fluids (3)

Metal working fluids (4)

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