Ind.gearbox by NK Modf Fm. Bock_Gear 02

Wolfgang Bock / FPOC-Industrial Oils / November 2002

Fig. 1

Gear_Shanghai_2002l_ATK_E_Q_Part1

Industrial Gear Oils

Performance Levels

Reduction of friction

Reduction of the oil sump temperature


Fig. 2


Spur Gear or Straight-Tooth Gear

Helical Gear

Spiral Bevel Gear

Hypoid Gear

rolling Contact (Line)

sliding Motion , Slip

Gear Types – Schematic


Fig. 3


Gear Types – Hansen Transmission


Fig. 4


Gear Types – L+S, Bosch Rexroth


Fig. 5


Gear = Machine part which transmits motion and force from one rotary shaft to another

electrical Energy Pelect mechanical Energy Pmech

mechanical Energy = Moment x Revolutions

Pmech = M1 x n1 = M2 x n2

Moment M1 = Force F1 x Radius r1

Function of Gears - Schematic


Fig. 6


Mechanism of the lubrication

Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG


Fig. 7


Load Carrying Capacity Test for Lubricating Oils

DIN 51354 Part 2, FZG A/ 8,3 / 90A = Particular Tooth Form

•High Sliding Velocity - One-Sided Profile Displacement•Scuffing and Scoring are affected by the Lubricant •Oil Sump Lubrication

PinionWheel

FZG Test - Load Carrying Capacity Test


Fig. 8


Load Carrying Capacity Testfor Lubricating Oils

FZG Gear Test Rig, DIN 51354-2~ CEC L-07-A-85Method A 8,3 / 90

FZG A/ 8,3 / 90A = Particular Tooth FormSpeed at the Pitch Circle 8,3 m/sInitial Oil Temperature 90°Cmax. Load Stage : >12

FZG A/ 16,6 / 140A = Particular Tooth FormSpeed at the Pitch Circle 16,6 m/sOil Temperature 140°Cmax. Load Stage : >12

FZG Test - Load Carrying Capacity Test


Fig. 9


Wear as a result of e.g.: low speedlow viscosityhigh oil temperature / thin film .....

Tooth profile with typical wear on the surface( wear is a continuous procedure, Face of tooth with wear on the tip of the gear tooth and wear on the root of the gear tooth )

Improvement with e.g.:higher viscosityEP/AW additives (chemical and physical )....


Wear/ Verschleiß on the surface of a tooth


Fig. 10


Tooth profile with typical scuffing marks on the surface (Scuffing/ Fressen = a result of a sudden damage) (normally not in the region of the pitch cicle )

Scuffing as a result of e.g.: middle or high peripheral velocitylocal high stresslocal high pressurecase carburized surface of the toothsudden damage...

Improvement with e.g.:higher viscosityEP/AW additives....


Scuffing/ Fressen marks on the surface of a tooth


Fig. 11


Comparison of Scuffing / Fressen Wear/ Verschleiß


Scuffing / Wear


Fig. 12


Micro-Pitting Capacity Test for Gear Lubricants

FVA Research Projects Nr. 54 / I -IV, 1993,GT (GFT) - C/8,3/90; GT (GFT)~ Micro-Pitting-Test C = Particular Tooth Form

•Balanced Sliding Velocity - more in Line with Practice•Influence of Lubricants (Additives) on Micro-Pitting •Spray Lubrication, 2l/min into the Tooth Mesh

Wheel

Pinion

GFT Test - Micro-Pitting Capacity Test


Fig. 13


Micro-Pitting Capacity Testfor Gear Lubricants

FVA Research Projects Nr. 54 / I-IV, 1993,GT (GFT) - C/8,3/90; GT (GFT)~ Micro-Pitting-Test

GFT (GT) , FZG C/ 8,3 / 90C = Particular Tooth FormSpeed at the Pitch Circle 8,3 m/sOil Temperature 90°CSpray Lubricationmax. Load Stage : 10 = high

C = Particular Tooth Form

Micro-Pitting Capacity Test for Gear Lubricants


Fig. 14


Tooth profile with typical Micro Pitting marks on the surface (Micro Pitting is a long term fatigue damage, normally in the root region of the tooth )

Micro Pitting as a result of e.g.: in different peripheral velocity regionscase carburized surface of the toothlong term fatigue damageinfluence of the additives...

Improvement with e.g. :higher viscosity / higher film thicknesslow friction coefficientspecial EP/AW additives....


Micro Pitting/ Graufleckigkeit marks on the surface of a tooth


Fig. 15


Tooth profile with typical Pitting marks on the surface (Pitting is a long term damage, e.g. in the micro pitting region of the tooth )

Pitting as a result of e.g.: in different peripheral velocity regionscarburized surface of the tooth or tough tempering surface of the toothlong term fatigue damageinfluence of the additives... Improvement with e.g.:

higher viscosity / higher film thicknessSynthetic Oilslow friction coefficientspecial EP/AW additives....


Pitting / Grübchenbildung marks on the surface of a tooth


Fig. 16


Comparison of Pitting Marks on a

Case carburized tooth( Einsatzgehärtet )

Tough tempering tooth(Vergütet )


Pitting Marks


Fig. 17


New Additive Technology - RENOLIN

Wear on the tooth flanks of gearsMicro-pitting behaviourFZG C/8,3/90 – FVA No. 54/I-IV

Middle

High

Low

Middle

High

Low

Micro-pittingLoad Stage

Micro-pittingLoad Stage

Old Technology

New RENOLIN

Technology

RENOLIN industrial gear oils pass micro-pitting

tests:

High load stage in- Endurance test- Load stage test


Fig. 18


Test results – Micro-pitting resistance Mean profile deviation at the pinion

(3 different tooth flanks)

0

5

10

15

20

25

5 6 7 8 9 10 8 10 10 10 10 10

mean p

rofile

devia

tion [µ

m] CLP-M

RENOLIN CLP 220

CLP-PGRENOLIN PG 220

CLP-EPLANTOGEAR 220 S

CLPF-MRENOLIN CLPF 220 SUPER

CLP-PAORENOLIN UNISYN CLP 220

5 6 7 8 9 10 8 10 10 10 10 10

795 945 1094 1245 1395 1547 1245 1547 1547 1547 1547 1547

KS

pHmax

Load stage test - 16 h per load stage (KS)

limit: 7,5 m mean profile deviation

Endurance test - 80 h per load stage ( KS)

limit: 20 m mean profile deviation

5

0

10

15

25

20

Pitting

= Hertzian pressure at pitch point


Fig. 19


FE8 – roller bearing wearroller element- and cage material wear, FE8 test rig from FAG, Germany

Wear of the roller elementsWear of the cage material

FAG GermanyFE8 – roller bearing wear


Fig. 20


240

2,6

1

10

100

1000

Old Technology

New RENOLIN CLP

Technology

We

ar

[mg

]

New Additive Technology - RENOLIN

Wear on roller bearing elementsFE8 Test (FAG) – Steel / Steel

D 7,5 / 80-80

V 50% roller

elements

Requirement DIN 51517 – Draft,

Year 2002:Wear of roller

elements max. 30 mg

according to DIN 51819-3

Roller wear [mg]


Fig. 21


Gear Oils

CLP

CL

Industrial Gear Oils

Foodgrade LubricantsAGMA 9005 / D94ISO 6743-6DIN 51515 / DIN 51502

Automotive Gear OilsAPI, GL4, GL5

CLP-HC (PAO)

CLPF (D) CKE – CKB + Frict. Mod.

CKD – R&O, EP/AW, HT

CKB – R&O

CKC – R&O, EP/AW

CKS – Synthetic(AW/EP – light), LT, HT

CLP-PG (PAG)

CLP(D)

CLP-E (Ester)(biodegradable

fluids)

R&O and EP OilsAGMA 2EP – 9EPISO VG 68 - 1500

Synthetic Gear OilsAGMA 0S – 8S

ISO VG 32 - 680

R&O OilsAGMA 0-6:

ISO VG 32 – 320

R&O Oils + Frict. Mod.AGMA 7 Comp – 460AGMA 8 Comp – 680

AGMA 8A Comp - 1000

CKT – Synthetic(AW/EP – high), LT, HT

H1 PAO

H1 USP White Oil

RENOLIN CLP

RENOLIN DTA

R. UNISYN CLP

R CLPF SUPER

RENOLIN PG

R. CLP PLUS

PLANTOGEAR S

Classification of Gear Oils

L = Anti Oxidant, Anti Corrosion = R&OP = Anti-wear, Extreme Pressure = AW/EPD = Detergent / DispersantF = MOS2 (black colour)HT = High TemperatureLT = Low TemperatureFrict. Mod. = Friction Modifier


Fig. 22


RENOLIN Base Oil CL CLP CLPDCLPF

(MoS2)

Extremely High

Oxidation Stability

High Micro-Pitting

Resistance

CL / DTAMineral

OilX

CLPMineral

OilX X X

CLP Plus Mineral

OilX X

X(light DD

properties)A.O. Boaster ! X

CLPF SuperMineral

OilX X

X(light DD

properties)X (X – medium)

RENOLIN – Industrial Gear Oils – Mineral Oil-Based Fluids, (P-S Additives)

L – Anti-Oxidants / Anti-Corrosion AdditivesP – Anti-Wear- / Extreme-Pressure Additives

D – Detergent / Dispersant AdditivesF – Contains MoS2 (black colour)


Fig. 23


Base Mineral Biode- Gear Performance Bearing

OilOil

Compati-grada-bility

FZG PerformanceHigh Micro-

Perfor-mance,

bility A/8,3/90 A/16,6/140 Pitting Resistance

FE8 Test

RENOLIN UNISYN CLP

PAO

CLP-HCYes No > 14 > 12

Pass

= High

Pass

Excellent

RENOLIN PGPAG

CLP-PGNo No > 14 > 12

Pass

= High

Pass

Excellent

PLANTO-GEAR S

POE

CLP-EYes Yes > 14 > 12

Pass

= High

Pass

Excellent

L – Anti-Oxidants / Anti-Corrosion AdditivesP – Anti-Wear- / Extreme-Pressure Additives

HC – Synthetic HydrocarbonsPG – Polyalkylene GlycolsE – Synthetic Ester Oils

RENOLIN – Industrial Gear Oils – Synthetic Fluids, (P-S Additives)


Fig. 24


Industrial Gear Oils – Specialities

Application Performance

RENOLIN MORGEAR Series Morgan Bearings

DANIELI Approval

According to Morgan Specifications

Mild / light EP/AW, good demulsibility

POWERGEAR Series Mining EquipmentGood emulsifying properties

For equipment with high water contamination

RENOLIN SPP UK – Steel Industry

Good emulsifying properties

For equipment with high water contamination

Mild / light EP gear oil


Fig. 25


Industrial Gear Oils DIN 51 502, DIN 51 517, ISO 6743-6, AGMA 9005-D 94

o Mineral Oils, CLP-M: e.g. RENOLIN CLP 220 e.g. RENOLIN CLP 220-PLUS Mainly „standard lubricants“ Universally applicable

o Polyalphaolefins, CLP-PAO: e.g. RENOLIN UNISYN CLP 220 For high operating temperatures Long lifetime Paints + elastomers = no prob- lems Miscible and compatible with mineral oil (ca. 10-20%)

CH3 CH3

CH3 CH3

CH3

CH3 CH3CH3CH3


Fig. 26


Industrial Gear Oils DIN 51 502, DIN 51 517, ISO 6743-6, AGMA 9005-D 94

o Polyglycol, CLP-PG: e.g. RENOLIN PG 220 Low friction coefficients („worm gears“) For high operating temperatures Compatibility with paints and elastomers ?! – Tests are required Not compatible with mineral oil ! High load carrying capacity, good wear protection

o Synth. Ester („Bio“), CLP-E: e.g. PLANTOGEAR 220 S Environmentally friendly Rapidly biodegradable Paints, elastomers ? (compatibility with esters) – Tests are required Low friction coefficients (clutch lamellar coatings) High load carrying capacity, good wear protection

H2C

H3C H2C C

H2C

O

O O

R2CH2

O R3

O

R1

O

RO

OO

OR

CH3

CH3

i j k


Fig. 27


Industrial Gear Oils Comparison of typical base fluid characteristics

Base Oil M. OilMineral oil,

e.g. RENOLIN CLP 220

PAOPolyalphaolefins,

e.g. RENOLIN UNISYN CLP 220

PAGPolyglycol,

e.g. RENOLIN PG 220

POEEsters,

e.g. PLANTO-GEAR 220 S

Viscosity at 40°C [mm2/s] at 100°C [mm2/s]

22018,4

= 100%

22025,7

= 140%

22034,7

= 188%

22028

= 152%

Viscosity index 95 150 200 160

Flashpoint [°C] 230 260 230 280

Pourpoint [°C] -18 -54 -33 -48

Water-soluble no no yes/partly no

P – Pressure-Viscosity-Coefficient at 40°C (ISO VG 100)

M = 1,94/kbar= 100%

PAO = 1,39/kbar= 72%

-- E = 1,25/kbar= 65%

Paints – Compatibility +++ ++ (ester share of ca. 2-5%)

Check! Check!

Elastomers – Compatibility +++ ++ (ester share of ca. 2-5%)

Check! Check!

+++ = very good, ++ = good


Fig. 28


Temperature range

according to: Flender GFT* Blatt 5

Mineral oils, CLP-M: -10°C to 90°C (short periods: 100°C) -15°C to 130°C

Polyglycol, CLP-PG: -20°C to 100°C (short periods: 110°C) -30°C to 180°C

Polyalphaolefins, CLP-PAO: -20°C to 100°C (short periods: 110°C) -45°C to 150°C

Synth. Ester („Bio“), CLP-E: -15°C to 90°C -30°C to 180°C

Lifetime at an average oil temperature of 80°C (according to Flender)

Mineral oils, CLP-M: 2 years or 10.000 h

Synth. Ester („Bio“), CLP-E: 2 years or 10.000 h

Polyglycol, CLP-PG: 4 years or 20.000 h

Polyalphaolefins, CLP-PAO: 4 years or 20.000 h

Contaminations (e.g. water, dirt, abrasion / wear products, acid gases, etc.) have a negative influence on the lifetime.

Temperature range and lifetime of Industrial Gear Oils

* GFT = German Association of Tribology


Fig. 29


Lifetime of Industrial Gear Oilswith regard to the oxidation stability: ISO VG 220

Rotary Bomb Oxidation Test RBOT – ASTM 2272 (2112)

0

0,5

1

1,5

2

2,5

3

3,5

4

Min

era

l Oils

CL

P-M

Min

era

l Oils

CL

P-P

LU

S

Po

lya

lph

a-

ole

fins

CL

P-P

AO

Po

lyg

lyco

ls

CL

P-P

G

Syn

the

tic e

ste

rs

(bio

de

gra

da

ble

)

CL

P-E

0

0,5

1

1,5

2

2,5

3

3,5

4

M.Oil PAO PAG POE

1 2-2,5 3,5-4 2,5-3 1-1,5

Test parameters: 50 g oil5 ml H2O3 m Cu-wireO2 – 620 kPaTemp. 150°C

The period of time is measured in which the oxygen in the autoclave has been used up.

CLP-M: e.g. RENOLIN CLP 220CLP-PLUS: e.g. RENOLIN CLP 220 PLUSCLP-PAO: e.g. RENOLIN UNISYN CLP 220CLP-PG: e.g. RENOLIN PG 220CLP-E: e.g. PLANTOGEAR 220 S

Life

tim

e f

act

or


Fig. 30


Cost effectiveness

• longer lifetime of synthetic lubricants (factor 2)

• Reduction of the oil sump temperature by ca. 10°C (factor 2)

• Reduction of service, waste oil, stop periods, ... (factor 2)

Compensation of the higher prices by:

0

0,5

1

1,5

22,5

3

3,5

4

4,5

Min

eral

Oils

CLP

-M

Pol

yalp

ha-

olef

ins

CLP

-PA

O

Pol

ygly

cols

CLP

-PG

Syn

thet

ic e

ster

s(b

iode

grad

able

)C

LP-E

Pri

ce f

acto

r

0

0,5

1

1,5

22,5

3

3,5

4

4,5

M.Oil PAO PAG POE

1 3,5-4,5 3-4 3-4

CLP-M: e.g. RENOLIN CLP SeriesCLP-PAO: e.g. RENOLIN UNISYN CLP SeriesCLP-PG: e.g. RENOLIN PG SeriesCLP-E: e.g. PLANTOGEAR S Series

Documents

Ind.gearbox by NK Modf Fm. Bock_Gear 02